Hello and CB650Z Cafe Racer build

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brown12633
Posts: 5
Joined: Tue Jan 03, 2017 10:42 am

Hello and CB650Z Cafe Racer build

Postby brown12633 » Thu Jan 05, 2017 10:59 am

This is another one of those projects in boxes that I promised myself I wouldn't do again. But the lure of a promised FULL bike and 2 engines for £199, well who could say no. Got up to rolling chassis and all parts appear to be present so gamble paid off. wiring loom bodged with numerous 240 wiring and crimp connectors as is the norm. Carbs appear top be good order . Plan at present it build up to rolling chassis and see if the engine runs then the dream begins.
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Folsoml
Posts: 1375
Joined: Sat Apr 07, 2012 9:02 pm
Location: North Florida

Re: Hello and CB650Z Cafe Racer build

Postby Folsoml » Fri Jan 06, 2017 5:22 pm

Welcome to the forum! That looks like fun. 8)
Have a problem with your CB650? Have a technical question? Click here!


My Current Bikes: 2005 HD FLHTCUI Electra Glide Ultra Classic, 2007 Yamaha Vino,

TonyStark7
Posts: 1
Joined: Fri Dec 16, 2016 10:37 pm

Re: Hello and CB650Z Cafe Racer build

Postby TonyStark7 » Tue Jan 17, 2017 9:13 pm

Cant wait to see the full build!

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brown12633
Posts: 5
Joined: Tue Jan 03, 2017 10:42 am

Re: Hello and CB650Z Cafe Racer build

Postby brown12633 » Sat Apr 29, 2017 10:51 am

Well its been a couple of months now and progress has been slow through one thing or another. However I have tackled the wiring which as normal has been hacked and bodged along its long life and with lots of added 240v wiring removed and proper connecting blocks replaced I have the basic wiring loom and more important a spark.
Even so I can only get her to turn over but not fire as it appears timing is out slightly and compression is down a little. Further investigation reveals timing chain is beyond its service limit, and as engine was going to be stripped down ive decided the engine rebuild is next job.
The next few pictures confirmed my suspicion for timing out that timing belt has jumped a few teeth hence unable to get timing spot on.

Looks like the camchain has been flapping around like a goodun for some time. Think the casings are still serviceable once a new camchain is fitted but I do have a spare engine that came with the bike so should be able to make one good engine out of the two.
I hate to think of how this engine must have sounded.

Anyone know where I can get a full gasket set top and bottom for this 81 model?
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Head of reveals slight marks where timing belt has caught casing slightly.
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Next Barrels show slightly more damage.
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And finally Crankcase damage.
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brown12633
Posts: 5
Joined: Tue Jan 03, 2017 10:42 am

Re: Hello and CB650Z Cafe Racer build

Postby brown12633 » Tue May 02, 2017 2:31 pm

The saga continues. continued the strip down of original engine but what a B$&@H. First there was no way in hell the alternator rotor would come off. Even with a puller or using the rear axle as suggested in the manual which now has a slight bend in it and knackered. But I plodded on and removed the sump and this fell out as in pic 2. and where it should be attached is as in pic 1. So will put this aside and try engine two.
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brown12633
Posts: 5
Joined: Tue Jan 03, 2017 10:42 am

Re: Hello and CB650Z Cafe Racer build

Postby brown12633 » Tue May 02, 2017 2:33 pm

And the fun begins again. 3 of the head bolts sheared off and one had a rounded head that even with special sockets I still couldn't get a hold and just made it worse. I had to turn out a collar in my lathe that would fit in the recess with a hole to fit a 16mm drill down dead centre and drill off the head.
4 hours later head off but cylinder barrels stuck solid. Is someone having a laugh with me. Tools down shed locked and relax.
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