Half-Caf: my '80 cb750f SS cafe project

[Half-Caf]

I got the new piston ring set a couple days ago. This time I got my roommate's help putting the block on -even then we still bent another one of the oil rings!
The problem was that the lower #1 and 4 pistons would get slightly angled as they entered the bore and the lower oil ring would get caught.
What we ended up doing was carefully tapping the top edges of the pistons with a stir-stick and then we crossed our fingers and pushed it down. SoOo glad that's over!

Since then, I've put on the head and have been stuffing it with the necessary components. One image that may be helpful to others is the horizontal cam chain tensioner. I took a pic of it in its place because you can't find ANY install info in the manual.



I also hooked up the gear-shift assembly that lies behind the clutch. At first I was having a lot of difficulty, but then I decided to screw the manual method and come up with my own.
Here is a shot of the completed assembly:


I put the roller/spring assembly in first (opposite of the manual)


Then I used a screwdriver to hold down the sprung arm while I installed the roller plate.

[Half-Caf]

Last night I put the clutch all together and it should be good to go.


Also, more head install pics. I got the exhaust cam in and looking good.


Here's a close-up of the oil fittings on the front side of the engine (I had to pull the valve cover of my 750 to figure out how where they installed)


After the exhaust cam, the rest was easy


Here's a shot of some of the middle bits and the oil pool caps

[Jefe06]

Half, been watching this build.  It looks real nice and clean.  Keep up the good work.  What are you using to clean your parts?  I've seen some other threads with parts cleaner info, but yours look spotless. Keep on brotha.

[Half-Caf]

Jefe06 wrote

Half, been watching this build.  It looks real nice and clean.  Keep up the good work.  What are you using to clean your parts?  I've seen some other threads with parts cleaner info, but yours look spotless. Keep on brotha.

Well thanks, and welcome! I've actually used a variety of things (different things on different parts) over the course of my build. One thing that worked pretty well was some generic degreaser from the $ store. coupled with a light rag, it works pretty well for that caked on, sludgy stuff.
For carbon build-up parts like my valves I did a CLR soak followed by a light-abrasive dremel wheel.
For heavy, stained parts like the cylinders and the head I used oven cleaner out in the sun.
And for just about everything else, there is the dremel and steel wool!

A lot of guys soak intricate parts like their carbs in pine-sol for a couple days -it does pretty well, too.
I just bought a gallon yesterday and plan on breaking up my bank tonight for some soak-time.  

[shinyribs]

Dude,you are moving right along! Right on! I havent even toughed mine in over a weekLookin'goodStill anxious to see the output shaft saga unfold. 100% confident you'll pull it off.No doubts!

[Half-Caf]

shinyribs wrote

Still anxious to see the output shaft saga unfold. 100% confident you'll pull it off.No doubts!

Well sir, this saga has already unfolded -in fact, I got the engine mounted up last night! I was literally giddy when the time came.

Here she is all ready to go..




And after quite a bit of wrestling I got it in and bolted!






Makes me one proud papa...

I took a shot of the sprocket setup for inquiring minds. The "conversion" was pretty simple (in concept, anyway) and only involved swapping out the 900 internal trans for a new 750 trans I picked up. The only difference between the two (once you remove the sub-trans) is the splines on the engine's output shaft.


The holes in the crankcase are a bit different, so I wasn't able to mount the 750 oil/sprocket cover, but I'm sure I'll whip something up

Now comes the fun task of piecing some things together! I would like to be up and running by the end of next week, so we'll see how things go.
Tonight I will be breaking apart the carb bank and poppin' that sucker in some pine-sol!

It feels good to finally have some momentum going with this build

[LukeM]

The paint and prep work are very pretty on this bike.  Taking your time, doing it right, paying attention to the details.

One thing I would recommend:
To put just one nick or dent or scratch on the bike by yourself, instead of having some cager/punk_kid  do it for you.  That way, it won't p!$$ you off when it happens the next time.

I remember it annoyed me for a week when my brand new car got its grille smashed by a radiator hose that fell off a flatbed truck 2 weeks after I picked it up. Lesson learned.

Luke M

[alfa750]

CONTENTS DELETED

The author has deleted this message.

[shinyribs]

Aw man,that was too easy! I was expecting  &  & & &  &


Glad it worked out easy for you.Like Luke said,dont get in a rush to finish up just yet! It'll all come together with plenty of time to ride.

[Half-Caf]

Ok, a little more info and a lot more pics!

I finally got my wheels balanced using that kit I bought. I must say, I'm pretty happy with how well it worked.


I also did some pretty heavy mods on my 900 axle to allow for my 750 wheel in the cbr forks.
Thankfully I have a friend who owns a machine shop


Now time for some carb work. Here's a couple pics of what they looked like when I tore them down:








All ready for a soak..


Things got a little weird when i ran out of brand name pine-sol


Apparently they are not quite the same thing


Now for the rebuild!
I went to guitar center and they hooked me up with some old e strings for those tiny passages


Here's a before and after shot of my emulsion tubes


Also decided to block my air-cut valves. I didn't have a handy leather punch, but I was able to get by with just a plain razor blade. (perfect circles are overrated anyway)


The new jets are 89 and 102 (what came with the rebuild kit I bought for my 750)
I didn't see any markings on the old jets, but they appeared to be the same size.


The dremel helped make things squeaky clean


Lookin' good


And all done!

[Piute]

Looking great 1/2 cow ,love those wheels,

[TOOLS1]

Looks GOOD! However I am curious about something. The jets look like they are in the wrong holes. Could, you have switched them?
Also, for a sprocket cover. Just use some small aluminum tubing to make spacers, and a piece of 1/4" aluminum plate to make a cover. That way, you would be able to see the cool parts, but still be protected.
TOOLS

[shinyribs]

That's a pretty cool idea Tools hadDid the chain alignment work out OK?

[Half-Caf]

TOOLS1 wrote

The jets look like they are in the wrong holes. Could, you have switched them?

I believe I placed them as according to the rebuild guide, However, I suppose I could have messed up...
Can anyone (read: seestheday) confirm that?

Also, I put the new front end on and it's out of alignment  I'm thinking it's actually the lower triple tree that's throwing things off. Good thing I have 2
However, getting that lower bearing off is going to be a bear -it took me a good 15 minutes with a hammer just to get it on

But, good news, too! I threw the front end on and sat a couple other pieces in place and this thing looks killer!

[Half-Caf]

OK, so despite the lack of updates, I've been diligently working on the bike.
Now I am to the point where it is completely assembled (sans seat, exhaust, and side covers)

I'm about ready to fire this puppy up, but something with the trans doesn't seem right...
The bike acts like it's locked in gear (can't push it more than ~4 inches) and I can only move the shift lever one notch (presumably 1st and neutral)

Now, when I rock it backwards I can hear a gear-type noise when it stops (normal: sounds like it's in gear)
However, when I hold the clutch in and do the same thing, it still stops, but no noise at all.
Is this cause for alarm?!

The engine is currently dry, but I'm afraid to add the oil only to find out there is something wrong with the clutch -or far worse, the trans...
Also, all of this was with the bike off and battery disconnected.

Thoughts?  

[Truck]

That frame/engine color looks killer.  I can't wait to see the finished bike!  Now just need to find my 900 so I can join in the fun

[Half-Caf]

She lives!
I was able to add some fluids and fire it up this weekend.



This video is the 2nd time I started it up (the first time was a little more smoky)
It still isn't really idling, and I'm sure the carbs need some fine tuning.

For reference, the mixture screws are turned out 2 full turns.
Next items on the list are brakes, tank, and seat.

[shinyribs]

Woo hoo!  Glad to hear it! Looking forward to watching the video when I get a chance. What did you find on the locked up issue.

[Piute]

                                IT's ALIVE

[shinyribs]