Half-Caf: my '80 cb750f SS cafe project

[shinyribs]

Half-Caf wrote

I've been busy with work, vacation, and a friend's wedding,

You put the bike on hold for all that?! Dude,where ARE your priorities?!?!

Ooooh,cartridges. I'm jealous nowKeep the eye candy coming.I dig pics.

[Half-Caf]

shinyribs wrote

Ooooh,cartridges. I'm jealous nowKeep the eye candy coming.I dig pics.

I think what you're looking at are just the massive spacers (basically chunks of pipe). I think the cbr did come with cartridge forks, but only starting in '94. Ironically enough, that's what the guy said these were, but the internals suggest 91-93.

In other news, I hope to finish cleaning up the head and finally slap the new engine together this weekend.
Am I correct in thinking that threebond 1194 is the stuff I need for the crankcase?

Hopefully I can find it in town because I'm itching to get this thing done

[shinyribs]

Ah,then jealousy subsided. You already have it ready to go back together? You got the 900 crank in? That was pretty fast!

[Half-Caf]

shinyribs wrote

You got the 900 crank in? That was pretty fast!

No sir-ee. I decided to see if I could just change the output shaft on the 900. They said a trans-swap couldn't be done, but that didn't stop me from trying!

[Half-Caf]

Ok, more progress!

Here are some pics of the engine post-paint:









Granted it's no "Tools powder special", but I think it looks pretty good for a couple of rattle cans

I did a little cleaning of the internals and threw on some assembly grease
Disclaimer: my roommate helped a bit with the process and decided to do a little photo-bombing


Instead of cannibalizing my 750 motor for its output shaft, I bought a new trans off of ebay ($40) and threw it in. Starting to look more like an engine!


People mentioned that the gasket sealer had a particular odor.. the fumes were indeed getting to us


Cases together and oil pan reinstalled


We went ahead and re-ringed the pistons and installed them as well.
By the way, do you like my engine stand?


Before I put the jugs back on, I decided to work on the carbon rings.


These were stubborn as heck  The only way I saw any progress was by carefully using some fine steel wool (sorry, no pic or progress -they look better )

I wanted to go ahead and assemble the rest, but as usual I ran into a snag....
I found 4 large o-rings not documented in either of my manuals but yet came with my gasket kit. Turns out that they go around the base of the cylinder sleeves.


I was only able to get one old o-ring (and about 1/3 of another) out. It took me about an hour and I broke several razor blade tips trying to pry that stubborn thing out of its little recess.

Any tips on removing old, stuck o-rings?

[TOOLS1]

It may not be a powder coated special, but it looks good, and, you probably have a lot more money left in your pocket.
I would use a dental pick to remove those O-rings. You can get picks at any hardware/automotive store.
I have a question about the breaks on that 81 front end. What is the diameter of the rotors, and how far apart were they?
TOOLS

[Half-Caf]

Last night I decided to throw my new tires on before returning back to those stubborn o-rings

Pretty much every shop I could find wanted somewhere in the range of $300 to mount and balance CHEAP tires (read: Kenda Challengers). Being both cheap and resourceful, I didn't even think about handing them over my rims (oh yeah, that price was for just mounting and balancing on bare rims.

Sooo.. got a set of Shinko 712's for around $90 from Motorcycle Superstore. Shipping was super fast, too!


I got a mount and balance kit off ebay for $60. It came with tire levers, rim protectors, balancing rod, and bearings.


Heck yeah for saving $180!

So, I put on some new tubeless valve stems and, with the help of a generous amount of soapy water, I mounted the tires.


I still haven't gotten the bead to completely seat, but I don't really have a compressor worth mentioning  There's a Midas at the end of my street -who knows, maybe they'll find pity on me, and let me use their compressor

As for the tires, they definitely look nice. It's hard to accurately gauge their size given the fact that they aren't seated or aired, but the front (100/90/19) looks mighty skinny to me..

 

[shinyribs]

Go to the nearest gas station. Put $0.50 in the machine and get some air :). Rims look good dude!

[Half-Caf]

shinyribs wrote

Go to the nearest gas station. Put $0.50 in the machine and get some air :). Rims look good dude!

Will the gas station have enough oomph to seat these puppies?
Also, its good to know that you approve of the "murder black"

[Half-Caf]

TOOLS1 wrote

I would use a dental pick to remove those O-rings. You can get picks at any hardware/automotive store.
TOOLS

Your recommendation is my command, sir. I picked these up on the way home yesterday


I was able to pick out some more of the plastic-y o-rings, but there is still some stubborn sections that are hard as a rock and refuse to budge
I've been trying some blaster on them, but I may need to look down the chemical route.

TOOLS1 wrote

I have a question about the breaks on that 81 front end. What is the diameter of the rotors, and how far apart were they?
TOOLS

The front end is off of a 1980 750f. I am at work at the moment, but I'm pretty sure the rotors are either 175 or 176mm. As for the spacing, I'll have to mount them up and find out.

[shinyribs]

They should. The one nearest my house will go to 60. Any truckstop will have hoses hanging at the diesil pumps. Free. As long as you don't block traffic they wont care.

[TOOLS1]

What ever happened to "free air"? I doubt one of those $.50 air machines would seat a tire. I would think any independent tire shop would let, you use an air hose.
TOOLS

[shinyribs]

TOOLS1 wrote

What ever happened to "free air"? 

I stole their sign....


Reminds me of a Raconteurs song:

"I'm paying for what should be free,
but I'm not buying what they're selling me"

[Half-Caf]

shinyribs wrote

"I'm paying for what should be free,
but I'm not buying what they're selling me"

Yeah, stick it to the man!
I ended up going to Midas and they helped me set the bead on both of my tires. The rear was quite the pain and made a loud firecracker sound when it finally snapped into place. But now wheels are done and out of the way!

I made some more progress on the engine last night, too -sort of...

See what's in this picture? No o-ring!


I got the new ones stuffed in there as well

Looks kinda like bubble gum

New gasket installed


And this is about where I ran into problems...


Although they're not pictured, I ended up putting some paint stir-sticks underneath the sides of the #2 and 3 pistons. They went on fine, and I even got all the rings of the #1 and 4 pistons in when I ran into a snag. I tried using a rubber mallet to tap the cylinders on, but the one side would not move.
That's when I removed the jugs and found this on the #1 cylinder


That's the lower oil ring. Apparently it got caught somehow?  I didn't even think the oil rings stuck out really!

I contacted the guy who sold me the rings and I think he's gonna sell me another single set for $20. Not a bad deal, but definitely sucks at this point...

[Half-Caf]

Ok, so I put together a checklist of items that still need to be done for my build.
Hopefully I can keep knockin' things off in the next couple of weeks

Remove 750 engine
Touch-up / buff frame
Make headlight assembly
Mount gauges, lights
Fab seat mount
Clearcoat tank
Fab axle
Paint engine covers
Assemble engine
Clean / rebuild carbs
New battery?

[shinyribs]

I just had a thought, and you may think this is hideous, but how cool would it be, since your blacking out your bike, to paint your star with glow in the dark paint?  That would be pretty Dang cool I think.

[Half-Caf]

Glad you think so

[shinyribs]

                               

[Half-Caf]

More progress. Remember that check list I made? Well, I've been checkin' things off left and right!

After some internal debate, I decided to go ahead and paint the side pieces of the engine black as well -this is gonna be a stealthy looking bike
The alternator cover was in pretty good shape, so I cleaned it up a little and taped of the center portion. Gotta have a little shine, right?




This is somewhere in-between prime and paint


With my roommates help I was also able to get the 750 engine out of the frame. It was pretty painless, too!
We just put the whole thing on a small dolly and then removed the frame.

[shinyribs]

Dude,you DOHC guys have it too easy on engine removal.I still dig the red frame btwProgress is lookin good