FRANKENHONDA II the 1982 DOHC CB 750F2 Build

I’ve realised that until the piston ring kit arrives, I can really start assembling the engine.

So instead I installed the pistons, I dropped the c clips for the gudgeons twice into the box luckily I was able to retrieve them with a magnet.

Next I replaced the seal for the oil pump, I broke a bolt for the oil pump when I was tightening it, luckily enough of the bolt was as sticking out that I could get it with a pair of pointy nose pliers

Then I polished up the timing and chain covers before replacing the seals and rubber rings. It’s starting to come up alright although she’s slow going with the polishing.

Tomorrow I’ll try to knock over the clutch cover and rotor stator cover then get them back on the engine


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cb250nproject said:
So instead I installed the pistons, I dropped the c clips for the gudgeons twice into the box luckily I was able to retrieve them with a magnet.

I always stuff rags around the connecting rods so that when the c clips drop or go flying (they always do) they don't go into the crankcase
 
advCo said:
I always stuff rags around the connecting rods so that when the c clips drop or go flying (they always do) they don't go into the crankcase

That’s how I ran after the second one, I think my brain may be in low gear ⚙️, I think it’s the whole baby sleep pattern that’s messing with me. He’s what I would call an intermittent sleeper .


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Maritime said:
If a bolts gonna break, that's how you want it to happen LOL.

It was even loose in the hole literally twisted with the pointy nose pliers a few times then by hand. That’s all my luck gone for the week now


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Well I’ve re polished the clutch cover and rotor stator cover, replaces all the gaskets then properly installed the sump plate.

Then I realised I’ve miss placed two bolts for the chain cover can anyone that has a cb750 DOHC tell me what length these are ??

After finishing I cleaned up the garage in preparation of putting the rest of the motor back together.

Hopefully Wednesday next week all my parts will arrive then I can put this bad boy back together. Tomorrow morning I’ll have a crack at the shims




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Wow, looking good Phillip. According to Partzilla, those bolts are 6x40, but you might want to double check that.
 
So I’ve put the cam in and put 4 of the 6 journals on, but I’m unable to rotate the cam. I’m not sure if this is normal, if I just need to grow a set and wrench it harder or if it needs to have the journals removed each time I want to rotate the cam


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So I just needed to grow a set, and oil the journals.

.005" for clearance is thousandths of an inch, and my feeler gauge is in mm so tomorrow I will get the right feeler gauge and continue hopefully the spare shims that I have will be enough to get the job done.
 
even thou feeler gauges come in mm, each step is 1 thou because that way they only have to make one set.

0.05mm is 2 thou, 0.075/0.08mm is 3 thou, 0.10mm is 4 thou, 0.127mm is 5 thou, etc.
 
It was in mm in the end. That was after I got another gauge

I ended up getting the shim chart out and did my best I could with the shims I had

Pretty much had everything around .08 - .10 but one shim was .15 so I need a 285 just to bet it back to .10 and I don’t have it.

Tomorrow I’ll do the shims on the intake side. Most places will be open again so I’ll be on the hunt for more shims once I have my wish list complete.

Being a ditz I did the first few with the head directly on the bench, rotating the cam by hand so I’m hoping I haven’t damaged the valves. Now I have it up on wooden blocks so the valves move freely.

Old Man Murphy gave me an update from his shed, this is the bucket that will house the speedo.



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I really hope you had all the shims in place while turning the cam over.

If a cam lobes hit a bucket without a shim in it, it can bend the bucket leading to all sorts of trouble. Like getting stuck and then piston hitting valve.
Just worry cause I saw all the shims out on your chart, but maybe they are extras?

The engine looks hot! Polishing it up like that takes time.


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Nybz said:
I really hope you had all the shims in place while turning the cam over.

If a cam lobes hit a bucket without a shim in it, it can bend the bucket leading to all sorts of trouble. Like getting stuck and then piston hitting valve.
Just worry cause I saw all the shims out on your chart, but maybe they are extras?

The engine looks hot! Polishing it up like that takes time.


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100% all the shims were in the buckets, the ones on the page were the spares I have collected unfortunately I still need to collect some more.

I found that even after I put what I thought to be the correct shim in, I’d have to rotate the cam another full cycle to get a true measurement. Maybe I just wasn’t seating the shims properly, the change wasn’t too drastic but still a little.

Polishing is hard work but the end result is satisfying. I would be interested to watch how the professionals do it see if there are any secrets to the art.

Really hoping my parts come in today, then I really have no excuses not to put this engine back together.


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So I managed to get the intake clearances done there are only two at .07 and .08 all the rest are .09 and .10

Then I had a bit of a set back, my ring kit came in so I rushed off to get it then installed it onto the piston, then got ready to instal the cylinders.

I put the gasket on, then a little 3 bond. I had the wifey assist lowering the cylinder so I could guide the pistons into the barrels. Then some how one of the pistons fell forward and got wedged on the bolts and broke the exact same ring but on a different piston. “Enter swear words here” then a small piece fell into the gearbox.

So far I have been unable to fish it out with my magnet on an aerial I’m not sure if I remove the sump cover if it may be in there

I just reordered my second ring kit, and left the garage.

Pretty frustrated so I think I’ll take the dog for a walk


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I am sure you got it but, when putting the cylinder back on, make sure that A cam chain tensioner is in there....it can be a common mistake, don’t ask how I know

Does the 1982 have o rings on the back studs, like the earlier models?

Sorry to hear about the broken ring
Sucks to be waiting all that time to build the engine and this happens. Keep up the awesome work, looking great!

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Nybz said:
I am sure you got it but, when putting the cylinder back on, make sure that A cam chain tensioner is in there....it can be a common mistake, don’t ask how I know

Does the 1982 have o rings on the back studs, like the earlier models?

Sorry to hear about the broken ring
Sucks to be waiting all that time to build the engine and this happens. Keep up the awesome work, looking great!

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I don’t think it does, but I noted 3 bond was around each of them when I removed the original gasket, so I intend to do the same. Can’t hurt.

I did get all 3 cam tensioners from Vince & Hyde

I tapped the two holes as per the installation instructions

Then I noted that one of the tensioners wouldn’t seat properly, but I put it in the vice and went over it a couple of times with a file then it was sweet.

Then I thought I would look at the switch gear for the handle bars I drilled it out and put a rubber grommet in.

Next I soldered the wires to each of the switches then I feed it through the hole and put the bar ends, but then when I went to feed the cable through for the handle bar indicators it wouldn’t all go through then as I pulled the wires out for the switch gear I broke one off.

Inside the housings of the switchgear there is very little room for the wiring and my soldering game is weak at the moment.

I’ve hung the soldering iron up for the day and I’ll have a crack again tomorrow.





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Update from Old Man Murphys garage. So had more progress on the bucket to house the speedo.

The speedo has two buttons on the back that cycle through the menus and reset the trip meter.So they could still be activated, OMM put some screws into the larger took the thread off and cleaned up the head so they could be inserted into holes drilled into the base of the bucket.

Last thing OMM will do is cut the slot for the idiot lights then it’s back to me for engraving and polishing.

Unfortunately today for me no shed time, I was re oiling the deck that should be finished tomorrow morning so I’m hoping to have the afternoon to sort the wiring out.


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