Topic: Well I'm back with a new project.

[calj737]

You need to readjust the rockers and run the test again, dry first then wet (oil in the CYLINDERS).

Loose rockers=no air in= no compression.

Yup, and that "sucking sound" is the piston on the downstroke trying to create vacuum by pulling the valve open... (I'm betting)

[westhewelder]

Ok will re adjust the rockers. I had them all adjusted when I did the initial reading and those were the numbers I got. I will re adjust them back start with taking the carbs off entirely and then do a wet test.

Also just to confirm when you do your adjustment you start with 1.4t then rotate one full turn and adjust the remaining valves. Is that only for cylinder 1-4 or is that across the board all of them?

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[MetroRedneck]

Start at 1.4 and do 1,3 intake and 1,2 exhaust.  Rotate one full turn to 1.4 and do 2,4 intake and 3,4 exhaust.

Grab the manual chapter 3.

Nice 650 - I have a 79.   Someone mentioned battery and capacity.  I'm using a LiFePo with no issues.  Always ready to go and I rarely ride more than 15 minutes.

[westhewelder]

Yup. Dug into my head and the valve seats need to be redone for sure should solve my issue with poor compression. Ya ya get to put the engine together a third time. Teaches.me for taking short cuts..

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[jgger]

Good that you found it........sucks what you need to do to fix it!

[calj737]

Short cuts always lead you to the end, though rarely in a time/money saving manner 

[westhewelder]

On the bright side I'm going to know this engine really well lol

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[MetroRedneck]

I'm not a fan of the tappet covers and the way the gaskets fit.  Last time I had mine apart I went ahead and re-threaded the cover holes so I could actually get them tight enough to not leak.

[calj737]

I'm not a fan of the tappet covers and the way the gaskets fit.  Last time I had mine apart I went ahead and re-threaded the cover holes so I could actually get them tight enough to not leak.

That's a bad idea actually. The O-ring is there to prevent the tappet cover galling the threads in the cover. Without that, you may well find your tappet cover permanently seized the next time you attempt to adjust your valves.

The O-ring provides both an oil seal and a tension "guide" for the "torque".

[westhewelder]

So just an update a few things going on not too much been busy with the kz440 bike we are flipping. And some family issues.

But anyways got a new tach speedo combo to eliminate the clunky old gauges. Started to remove the tabs on the frame cleaning that up some holes to fill yet. Might clean up the wiring and working on a component tray.

 Might blow the motor apart again still getting compression issues on cylinder 2 and 4 75 psi compression while 1 and 3 have 100psi.

Looking for a good set of levers and master cylinder since my rebuild kit is 80$ I can buy new levers for 150ish. Now pcs for all that are interested

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[westhewelder]

More pictures

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[westhewelder]

So a question about doing the rear hoop I found a previous topic stating that the rear suspension bottoms out at 91mm of travel is that height of tire vertically or is that shock compression. I want to do a brat seat because it could accomedate 2 riders if need be. Am I doing this correctly if the stock dimension stud to stud is 340mm and I set it to 250mm would that give me the room I need. If so I don't see the point of this mod as bottoming out would be fairly likely.

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[MetroRedneck]

I'm not a fan of the tappet covers and the way the gaskets fit.  Last time I had mine apart I went ahead and re-threaded the cover holes so I could actually get them tight enough to not leak.

That's a bad idea actually. The O-ring is there to prevent the tappet cover galling the threads in the cover. Without that, you may well find your tappet cover permanently seized the next time you attempt to adjust your valves.

The O-ring provides both an oil seal and a tension "guide" for the "torque".

Still have all the o-rings and seals.  Just new threads for the fancy covers and cover bolts to tighten against.  The 650 has the three covers with gaskets.

PO had stripped about half of them out so they didn't tighten and used hondabond or some other sealant unsuccessfully.  Seems to be a common theme on my Hondas.

[MetroRedneck]

Looking for a good set of levers and master cylinder since my rebuild kit is 80$ I can buy new levers for 150ish. Now pcs for all that are interested

I'll check my 650 stash.  I think I have a lever or two.  I have a mc from a 550 that functions but is on original rubbers I'm sure.  I don't know what the bore difference is if any.  Looking at your pic, I don't know if that's the original anyway.  I had a different style on my 79.  Not sure if it was changed.

[westhewelder]

My options are rebuild the originator 111$ or buy a complete aftermarket nicer styling for 80. Pretty easy choice if I have to say so.

So don't ask me why but I'm not happy with how I put the top end together on this motor. I think it's going to get cleaned up again.

Might make some changes when it come to paint going to go a red frame with gun metal grey tank.

Aesthetically speaking would like to go with a rear hoop maybe a brat with optional cafe cowl. I like having the option of 2 up

So I guess first thing is first get my metal work done on the frame and seat. Then I can send that for blasting and powder.

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[SOHC4 Cafe Racer Fan]

My options are rebuild the originator 111$ or buy a complete aftermarket nicer styling for 80. Pretty easy choice if I have to say so.

So don't ask me why but I'm not happy with how I put the top end together on this motor. I think it's going to get cleaned up again.

Might make some changes when it come to paint going to go a red frame with gun metal grey tank.

Aesthetically speaking would like to go with a rear hoop maybe a brat with optional cafe cowl. I like having the option of 2 up

So I guess first thing is first get my metal work done on the frame and seat. Then I can send that for blasting and powder.

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Just my $0.02 but a brat-style seat is not very comfortable and REALLY not very practical/safe for 2-up riding (nothing for the passenger to sit into to keep from sliding off the back).  Most people who have brat-style seats acknowledge that the bike is not comfortable for more than in-town, low-mile trips.

[westhewelder]

Any suggestions for a nice seat that is comfortable and doesn't look like a office chair? I do have an appreciation for the cafe style seat but is that any better for a solo rider?

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[SOHC4 Cafe Racer Fan]

Any suggestions for a nice seat that is comfortable and doesn't look like a office chair? I do have an appreciation for the cafe style seat but is that any better for a solo rider?

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You are really only limited by your imagination.  If you don't like the bulk of the stock seat, you can trim down the foam and make it a lower profile seat with decent cushion and less mass.  I believe Camrector did this on his most recent 650 engine/550 frame build.  You can also add stiffer foam and/or a gel insert.

Café-style seats can be comfortable and supportive depending on the thickness and density of foam used; a seat hump also provides a natural backstop keeping you from sliding rearward on fast acceleration. 

If you want something turnkey, there are still some options.  Check out Motolanna (similar if not the same seat used by Cognitomoto for its 550 build).

[westhewelder]

So here's some update pictures and a fair few things have changed on the bike quite a bit...

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[JoeCooley]

Good progress! I really like the red frame but your shop floor looks like a crime scene. Why not put down some cardboard?

[westhewelder]

It was covered in oil none of the paint will stick. I'm going to do a good paint and clean this summer anyways I think.

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[westhewelder]

So today will be a clean up day for stray tools and now is the fun part all the parts are going on for good pictures to come.

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[westhewelder]

Cleaned house today ģot carbs in wiring harness in need to figure out what I want to do for and electronics box. I don't like the idea of the battery on the swing arm. So I have a couple other ideas

what have people used for mounting custom made seats and electric boxes?

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[westhewelder]

A couple pictures cleaned out the tank and welded up a polished the component tray. Also managed to find a 7" bucket.

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[westhewelder]

I've been busy lately with work running my side business and such. So here's an update where we left off. A lot has changed I've gone through 2 frame color and 3 tank paint jobs as well as 3 seats that I just couldn't get to a point where I was happy.

 Started going through the wirong harness finding the gremlins broken wires here and there, cleaning up the running of the wire and component locations.

 I still have a few odds and ends to pick up looking and exhaust designs. I am glad how ever I decided to give spare motor the bottom end of the gear case had a blow out in one of the cylinder bolt holes. I don't think I can weld it without warping the surface unfortunately.

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