Topic: '80, '81, '82, '83 CB650 (cleaned up and rebuilt)

[rb550four]

  Holy cow! Someone actually broke into your shop, didn't take your tools and knew that your float bowls aren't adjusted properly. So they turned the petcock to the on position knowing that the full tank of fuel was destined to be on the floor by morning? Why that sonofa#$%*! Sounds like an inside job to me.

[starsnbars89]

  Holy cow! Someone actually broke into your shop, didn't take your tools and knew that your float bowls aren't adjusted properly. So they turned the petcock to the on position knowing that the full tank of fuel was destined to be on the floor by morning? Why that sonofa#$%*! Sounds like an inside job to me.

Well, most of my tools were locked up so that's their story--though I've had tools stolen in the past. As for the float bowls (though they don't have adjustment anyway), they opened the drain screw on the #1 carb, letting the bowl drain while the petcock was open (it would be impossible to adjust that out of there!). From there, it doesn't take rocket science to figure that a good portion of the tank would be on the floor soon after. Since none of this seems like a conventional break-in anyway, I figure it was a message from my wonderful, lazy, redneck neighbors (complete with their pet pig) to sabotage my bike. I've had several heated occasions with them before and they have strongly voiced their opinions about my "piece of $!*^" bike and where they desire it to go when I wreck it (and it ain't the junkyard ). Paired with the fact that I told them the next time I find their pig doing it's business in my yard, I'm having some fresh bacon, it's a fair guess as to who is suspect. Sad thing is, I've called the state boys in the past and they told me that they can't do anything since, and I quote, "leaving the doors open during the day is INVITING people to break in." However, I'm to promptly call them the moment I notice someone in there. This is what the world is coming to...

Note: the average response time in this area is anywhere from 40min. to 4hrs. True stories: a close friend of mine almost died because we had to drive her to the hospital after waiting 1 1/2 hours for an ambulance that never showed! When a friend of mine's house caught fire, we had to wait 28mins. for the crew to come a few miles down the road; by which time, the house was a roaring blaze. One of my other elderly neighbors had to wait 3hrs. 45min. for the police to respond for him. And people wonder why we need guns!?!

[rb550four]

That is a ballsy move on your neighbor's part, stupid and un-neighbor-like. It always saddens me when I hear of the guy next door, the one's that you should be able to count on in any emergency, acting in such a way that could only provoke anger. Life is short and tough enough already. I'm sorry to hear that this has happened to you.

[starsnbars89]

Yeah, I'll give them that, it was pretty ballsy. But I try to keep to myself and not provoke anything. Not everyone in this town is like that; but in a small, redneck town like this, there are a few. I have no problems with most folks here though; and those jerks next door have a few problems of their own. I kinda feel bad for them, really and I'm trying to diffuse the tension as I can. I helped them get their Cavvy out of the snow the other day and the mom thanked me--though the sons have too much of an ego for that though. Buuuut, crap happens; and you're right, life is short. I try not to get upset over the stupid things. It's only gasoline and money--they make more everyday! Bike still runs, and it probably cleaned some of the grease off , so no harm done really.

[nitroeagle]

Sounds like normal. I did the headgasket on mine for the normal leak, still seeped some. Then spent a bunch of time trying to get it to run right. It helped when I found 2 loose head bolts. Adjusted the valves, upped the mains to 125's, & put some harley mufflers on it. It was better, but not great. At least I was able to ride. I ended up getting rid of it & picking up an '07 vulcan 500 for $200 less then I sold the honda for. Now the boss can ride too & I'll feel better about some long rides. Of course I'm getting the itch to cut up a bike again, but that's normal. Keep plugging away at it & good luck.

[starsnbars89]

Now the boss can ride too & I'll feel better about some long rides. Of course I'm getting the itch to cut up a bike again, but that's normal. Keep plugging away at it & good luck.

I have no boss to worry about as of yet; though I do look forward to the day! But for now, I'm still sticking with my faithful little machine with all her little problems and quirks. I'm on the steady but slow uphill climb to try and become some semblance of a mechanic, so I'm sticking with it whether I blow her up or not because I know that it will be a learning experience.

As for recent work done to her: I tore out all the jets and the needles from the carbs without pulling them from the bike ('cause those homemade boots are a friggin' trip to try and pry back on, especially in the cold!) Ordered some tiny little washer to use as needle shims (30 pack, so I'll have some for the future ). Also ordered a smaller taillight for my new rear fender, seat, and taillight mod. Waiting to get bigger jets, just need the funds--motorcycle "pot" is running dry.

On that note, someone offered me a 1977 Kawasaki KZ650 B-1 (std) that runs but needs some TLC. He's wanting to trade for my 1981 KZ440 LTD that doesn't run (needs a new pulse coil). Sounded too good to be true until he told me he "doesn't currently have the title but can give me the previous seller's info to try and get it". I don't know. I'm thinking that trading a smaller, titled bike for a larger, un-titled bike isn't TOO bad. Even if I can't ever get the title, I can part the old girl out.  And I would have my KZ650 pistons to play with! Sound like an OK deal?

[starsnbars89]

Got a couple more things done; nothing major. Made a fork brace out of the bracket for the front fender (the one I twisted up last summer ). Also started mocking up the rear fender/taillight/seat design (thank you, steved650, though I did change the design a bit ). Need to keep shaving down the seat more to what I want then I'm going to attempt to recover it myself. We'll see how it goes!


Fork brace





I need to mount the light higher still, fabricate the license plate mount, and paint it all still. That, and finish the seat. Should be OK when I'm done--nothing compared to Steved650's original awesomeness though!

I also ordered a new exhaust stud to replace the one I found broken. Once it comes in, she ought to be in at least a little better running order! Especially since it's supposed to be in the uncanny 50's this week!!

[starsnbars89]

Well, I got her done! I used the original seat cover so this technically isn't the final product, but it is sufficient for now (this is a TIGHT budget bike, remember!). Still need to paint up the bracket and clean up some wiring, but this is pretty much it.









Again, this isn't nearly as sweet as steved650's, but it's my best attempt with my EXTREMELY limited tools. (Note: this was accomplished with a recip. saw, pliers, a couple sockets, a bench grinder, and a really big knife; all using random parts found around the garage!) I'm proud of it.

[rb550four]

That doesn't look bad from here. The lack of tools doesn't look like it hurt you much. When I was a teen back in the 70's, the electric carving knife just hit the market,It worked great for cutting down seat foam, parents didn't like the idea much and was a sore subject at Xmas and thanksgiving. When I go to flea markets I still look for one.

[starsnbars89]

Well thank you! I didn't even think of an electric knife! I almost bought one once at Goodwill too! I used a 10" knife I carried as a machete when working on the farm. Worked pretty well for carving and taking down large areas. I then used a razor blade and a wire brush to smooth and shape the seat. The cover was the original that I stitched up and patched on the underside with denim. Not the prettiest, but I plan on recovering it with some fresh material when the budget allows. This IS a BUDGET build!

[curemode2002]

+1 on the looks I have seen a ton of guys local with way more tools in the shed come out with some nasty hack jobs

Yours looks like you took the time to do it right

[starsnbars89]

Woe, doom, death, dismay, and despair... I blew my head gasket today ... and I did it in a ridiculously stupid and irresponsible way to boot! This is the OFFICIAL time for a complete rebuild now.

Here she was on the road yesterday!



The forks tied on the back are the original ones off the bike that a guy is buying tomorrow. Oh, yeah, just polished up the "points" cover too.

[starsnbars89]

FINALLY!!! I did an engine rebuild. Now this isn't a final build, just one to get out riding for now--so basically, I didn't do a blasting, or heavy mods, or anything like that. Strictly tear down, clean, service, re-gasket, and put it all back together. Call it practice.

This is what Thursday looked like.

[starsnbars89]

Frame cleaned:


Parts cleaned:


Engine cleaned up and back in:




New valve seals in:


Head cleaned up:

[starsnbars89]

Engine back in and in time:


Cam cover back on and valves set:


Valve covers back on. Note the rockin' awesome "chrome" starter cover (chrome paint isn't as bad as I thought! )





Finished!



 

Now I need to address the carbs. She's backfiring and sputtering horribly at low-mid RPM's. Pilots are 35's and mains are 112.5 (down from stock 118's--PO's jobber). K&N air filter in stock housing with baffled but "open" headers. I'm thinking that if stock was 118, I should do a 120? 125? Shim the needle up a bit and call it good?

I also read on here about Soos putting on CVK carbs from a GPZ600 (Ninja ZX600 here). I might go that route here in the next few weeks but I'm looking for some feedback. Seem like a cool idea? Here is the original thread: http://forums.sohc4.net/index.php?topic=40287.0


BTW: Thanks guys for all the wisdom, knowledge, and experience I've gleaned from this forum! This place is awesome!!!

[seanbarney41]

This thread rules!  Seriously, I have tons of respect for those that have to do this stuff down and dirty budget style.  Where is the accomplishment in..."tore down a nice bike that I paid too much for, bought all brand new top o' the line stuff, put bike back together"...   Stars and Bars, your bike is improving as result of your hard work and ingenuity.  Keep it up sir.

[starsnbars89]

Well thank you very much, kind sir! The Lord has definitely blessed me with some base foundational skills and the ambition to delve in and learn! Seems like those are usually the perfect combination. I would definitely agree that there is FAR more satisfaction in doing something yourself; getting down 'n dirty and learning about it, but some people just don't have that gifting. They don't think they can do it so they don't. In my eyes, that's fine too. I would rather have them take it too someone like me (or perhaps a professional ) to get it done right instead of tackling it themselves and ruining something that was OK to begin with. I definitely don't think loads of $$$ is necessary for this kind of work though! Even with the price of parts these days, putting some elbow grease in and taking the time will save LOADS of cash to put in to the necessary expenses.

It's great to have mentors and teachers to learn from to. There is no way I could have done this build and came out with a running engine without having worked with the men I've worked with and learned from--not to mention the PAGES of info on this forum! The technical things I've learned from this place has pretty much turned me into the local CB guy.