1979 CB650 Cafe Redo - update march 31

[CresentSon]

Re: 1979 CB650 Cafe Redo - quick update

I look at it this way, I'm building myself while I'm building a bike. The extra expense is for personal maintenance and upgrade. It is frustrating but hang in there, it is well worth the headache. Plus the bike will mean a lot more since it has so many stories and unique challenges attached. Just my thoughts, hope it helps.

 

[Staffy]

Re: 1979 CB650 Cafe Redo - quick update

I agree Crescent. At the end of the day, a fool will rush in with no idea, and will make a mess of it. Yet the wise people that we all are, seek out the information, get the advice and share what we learn for the benefit of all. We are in effect doing an apprenticeship as a collective. If you don't try you can't learn.

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - quick update

Thanks for the encouragement guys. I didn't mean to sound negative. I meant exactly what you said Daniel it's a learning experience that only solidifies knowledge that hopefully I can pass on.

With that head though, I should have been more cautious but that isn't in my nature. lol

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - quick update

FINALLY, getting to laying paint on some of the parts. I've decided on the standard gloss black so I've gone with the appliance epoxy on all the frame bits. The tank, cowl, fenders and (undecided) headlight bucket and covers will get hit with a metallic orange/gloss black/silver stripe combo.
I've been lusting over a metallic orange for this bike and finally had the nerve to go to the Car Quest here in Guelph and ask if the do spray bombs. I really hate asking people for stuff. And they do. 15 minutes and 2 paint catalogs later I've the orange I want. No quite copper, not quite bright orange.

The parts hanging in my "spray booth"

And the orange colour. I know there are a couple of dents in the fender that need to be sorted out, but not bad for spraying in the near dark. Love that colour and in the right the the flakes pop. I'm very happy about this as I went back and forth about spending the money on it. $30 bucks for a can compared to 12 from crappy tire. But this is better quality paint by far.

Here she is.

She is bright. I think it'll look the biz with the gloss black engine, some polished parts and offseting that I blasted my covers to give it a sand cast finish for a little texture. (Thanks for the idea Swagger)

It's a real push right now as in 5 weeks we're down in the states traveling from Guelph, to Arizona to San Fransico to Black Rock, Nevada back to Guelph. It means get the RV ready for the trip, wifes friend is getting married, Traditional Indian wedding so that is 3 days she's gone so I have the kids. Don't think I'll get this finish before then. but the goal is to ride this year.

Later Gents

 

[Staffy]

Re: 1979 CB650 Cafe Redo - quick update

Looks familiar....

 

[CresentSon]

Re: 1979 CB650 Cafe Redo - quick update

Love the colour. That will surely pop off the black quite nicely. Just orange enough to command attention without annoying the senses...

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - project on hold but looks what's to come

I start my vacation next week. It's an epic journey of 3 weeks with my father, siblings, their spouses and children. Going to take us from here to hopefully San Francisco and back. We'll see.

The bike build had slowed down as I was working on our project RV for this trip but the project RV is too much of a project to trust it to the 1000s of km/miles we'll be doing so plan B is in action. However I was able to get a few things done this week. Some final painting, and just some touch ups. When I get back I intend on blazing through the rebuild as I'm sooo close I can taste. Ported and polished heads on the engine and a 4-1 exhaust should force to me to rejet the carbs but that's the price I'll pay gladly to only ride this bike before the snow flies.

And now, here's where she stands.

I love the colour and with 3 weeks away from the girl, it'll give me time to think on the graphics for the tank. Suggestions welcomed.

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - project on hold but looks what's to come

oh, oh redflagged for no replies in my topic for 30 days. Sheesh I'm bad.

Finally she's a roller. There are things that aren't completed to what I envisioned, because it's been 2 years and I'm anxious to get it on the road for a day of riding before the snow flies. Knowing my luck it'll snow next week, or if I don't complete the bike we'll have an Indian summer.

Finally decided what I'm going to do for the indicators. going to mount them on an aluminum piece, cut and wire wheel brushed and mounted to my headlight with some VHB tape. Here's the process of that. My homework and the kids homework.

And I know that the bottom LED is slightly off so I made a new one. It probably wouldn't be noticed by 99% of the population but I'm the 1% that matters and it would piss me off. I'm cool with chipped paint, and scratches but don't screw with symmetry.

Spent a few hours last night getting the front back on. Sanded and wire brushed the home made aluminum headlight ears. All Balls steering stem bearings greased and installed. Shaker tach and speedo gauges mounted. I need to get the faces made that's why the caps aren't on. Measured how much I need to shorten the clutch and throttle cables. Installed the shortened brake lines and we're almost there.

Side View.
Seat is getting just a bare bones closed cell foam pad.

How the whole front flows, I'm really loving this flow.

Cockpit view

Tonight the engine goes back together. I've been putting it off because I just don't want to screw it up but it needs to get done so I'll bite the bullet. After that its wiring, tightening the bolts, fuel and hopefully, VROOM.

 

[Tim]

Re: 1979 CB650 Cafe Redo - She's a roller.

Those first few thumbnails launched this into my head.

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - She's a roller.

lol, Great now its called The Homer.

 

[Swagger]

Re: 1979 CB650 Cafe Redo - She's a roller.

DOH!!

 

[teazer]

Re: 1979 CB650 Cafe Redo - She's a roller.

Sleeves are typically pressed in at the factory and the way to get them out to replace them is to heat teh barrels and let them drop out. That's what happened here if I understood you.

You have options, but I'd take the barrels to any auto machine shop with a hydraulic press and have them press the liners back flush. It should be inexpensive.

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - She's a roller.

Sleeves are typically pressed in at the factory and the way to get them out to replace them is to heat teh barrels and let them drop out. That's what happened here if I understood you.

You have options, but I'd take the barrels to any auto machine shop with a hydraulic press and have them press the liners back flush. It should be inexpensive.

Cool, teaser. Luckily for me I had another so I'll worry about getting those fixed over the winter when I rebuild the spare engine. Just need to find a reliable place around here.

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - She's a roller.

Now that I've moved my ignition switch from the triple tree to my seat pan, I won't be able to use the original Honda ignition. It's too large to fit in the location so I replacement had to be found. Luckily for me my spare parts box held a Yamaha ignition that with a little work would be perfect for the location. The only problem is the connections. The Honda is a 5 pin and the Yamaha is a 3.

A look through the wiring diagram shows that with a little electrical wizardy I could work.

my chicken scratch figurins'

A silicone Diode to prevent electricity looping back. Basically when you turn the switch you turn on everything, however with the Honda switch, you put it in park it will turn the taillights on without going through the main power.

All sealed up

The guts of the key switch, getting cleaned up and re-greased.

As well I had to move the location of the fuse box to under the seat as I cut off the mount location on the top tree. I wanted a way to mount it under the but it would've been exposed so a solution for that had to be found, off to the junk box and low and behold I was able to come up with something.

The original fuse box for a yamaha sr250

All of this will be removed for the Honda fuse

The Honda fuse panel was too large to fit in the box so a little trimming...

With the yamaha fuse connectors removed from the case and 2 tiny screws later the Honda panel was in.

Now I need to wire LEDs for the indicator panel. I'll be using the original connectors shell for if I need to remove the headlight it'll just come apart. Plus I like to make it look like an OEM wiring harness.

That's all for now. Thanks for watching.

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - She's a roller.

With the engine half finished I wanted to see how it would look. I think it looks the right part to be honest. I love the orange paint, the look of the the triple tree. for now because I want to give it a ride before the snow flies I'm going with the original foot pegs but over the winter I'll be building some home made rearsets.

Seat foam purchased from Pat Cowen of Paco motorstuff.

I love that empty space there under the seat but I'll be running with the original airbox and battery so it'll be filled up. I ride in all weather so pods just don't seem to be a good idea in the rain. Plus I've heard they are a bitch to setup with this bike.

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - She's a roller.

I'm trying to get the o-ring into the rocker arm cover and it's a tight so it slips out one side, fix that, comes out the other side. That went on for half an hour before I had enough. Any suggestions to get this to work? Boil it to heat it up and have a little more stretch? glue it in? Any suggestions welcomed.

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - Breathing Fire, Kinda

Got the read flag for not posting in 30 days, lol.

No pics but finally after a couple of wiring issues and other time constraining setbacks. (aka other builds), I've got her to almost running condition.

Tried to ignite her for the first time since a complete tear down and rebuild. A little cursing and swearing, some quick start and she kicked off into life. Wouldn't run without quick start at first because I didn't have the airbox or filter on, but as soon as I cover inlet for the intake manifold with my hand she stayed alive and running. Now the heads have been ported and polished and the bike is running a 4-1 exhaust, my question is if it's only runs with air restriction does this mean I need to adjust the jets for bigger?

2nd problem - as soon as I turn the key in the ignition is seems to drain the battery and doesn't have enough juice to crank the starter. Any info would be greatly appreciated.

jay

 

[Big R]

Re: 1979 CB650 Cafe Redo - Breathing Fire, Kinda

I want to say yes, you'll need bigger jets.

As far as the battery goes, is the battery on it's last leg? Or maybe there's a short somewhere that is sucking up all the juice.

Either way, glad to hear you're back at it.

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - Breathing Fire, Kinda

cool Rich, thanks for the backup, sometimes when you've been working on something for a long time it's nice to know your thinking is on track.

As for the battery it isn't 100% so a new battery is in the works.

I'll post some pics soon.

 

[jay_kent]

Re: 1979 CB650 Cafe Redo - Breathing Fire, Kinda

so just a bit of an update carbs have been off-on-off-on-off-on. I'm a master at getting those bastard bank of carbs off and on that bike.

Carbs were leaking, had the floats adjusted wrong, back on and now only one bowl is still leaking out the overflow. But I'm suspecting a sticky float. so it'll be back off again. 2 days ago the bike was running on its own, albiet still with the choke on halfway, make the adjustment to the floats to stop fuel from overflowing and yesterday no running starts but dies . Four carbs are a bitch to work on. Anyhoo, we're making progress. Slowly.

Here's a quick pictoral tutorial on how I did my cables.

Cold chisel worked the best for a sharp clean edge on the cables. I used it on the housing as well. I removed a section of the plastic outer wrap on the housing then at split in the metal, that's where I put the chisel. No pic of that sorry.

A view through the end. I pushed an awl to spread the wire open so the solder will flow through everything.

Fluxed the hell out of it.

The solder I used. Bought from Canadian Tire

The finished ends. The larger end is actually brass wire wound around the smooth end of a drill bit that gave me the correct diameter that was needed. A little filling and tada instant cable end.

I need focus, seems my stable is full of steeds that need my attention.