1978 z650

Kingisabella · #1 12th March 2016, 02:25 PM

Took this yoke off the road in April 2015 and took most of it apart until recently. Bike was left out the back in the elements until recently, with the exception of all the boxes that were all over the house. So in January this year started the bike restoration course in St. Johns and rented a garage which was the kick up the ass I needed to get going. The aul fella did a good job of it while I was away, but again it was my only mode of transport and driving 70km of country roads to work in the rain did it no favours. So finally got moving on it, and reached the point during the week of stripping it down, to working towards putting it back together. Want to get it in good enough condition and keep it for the good dry and special days.

The plan was to lower the clocks and front to make it flush with the height of the tank, take a bit off the back to sit snug into the seat, finishing around the back axle, do all consumables and servicing jobs, C&S, all bearings, seals, oils, rejet carbs, and try and learn a bit about the inner working of the engine, cam chain tensioning, valve clearances, check what if anything in the engine needs doing and hopefully continue the bike restoration course for a next session and focus my attention solely on the engine and do what needs to be done on that, or what would be worth doing to freshen it up, with a bit of supervision & guidance. Just want to get it to a good enough condition and keep it that way really!

Kingisabella · #2 12th March 2016, 02:30 PM

Shortened the tail to where I wanted it roughly, should finish within an inch of the rear axle, which is enough to shorten the seat on the bike and leave the hump on the back as is, should be a snug fit single seat which is what I wanted it. It always looked too long, and riding youd either slide back or forward depending on throttle or braking.

The aul fella was a spray painter in his day so gonna do a DIY job of the frame to freshen it up. That should start later today.

Kingisabella · #3 12th March 2016, 02:39 PM

The axle stands proved untrustworthy...

The pipes under the wrap werent in great nick either, but not rotten by any means, and im planning on keeping them wrapped regardless.

Pre-garage time, and cheers to Airman on here for offering to drop the carbs in his ultrasonic cleaner, apologies I havent been in touch since! Up the walls!

Going to invest in a set of k&n pods, and with the harris 4-1 I think starting with two sizes up on the main jet is good start for rejetting.

Not entirely sure why theres charring on this, someone might have some idea if theres a cause that needs addressing?

Kwak · #4 12th March 2016, 05:37 PM

Keep up the good work , hope the end result is worth it .

Pumbaa the warthog · #5 12th March 2016, 08:28 PM

Fair dues lad.

Kingisabella · #6 12th March 2016, 08:33 PM

Just to clarify, the pics in the first post were before pics, I got it as black all over in 2013, crashed it in October 13, threw it back together war wounds and all and drove it around until summer 14, while I was away the auld fella painted it silver and tidied up a few bits but driving it everyday in shit weather made it worse than I ever wanted it to be so called for this!

NODSTER · #7 12th March 2016, 09:20 PM

Nice one Kingster, keep this thread updated on the auld progress

iano · #8 12th March 2016, 09:38 PM

wud you make me a cuppa?

Kingisabella · #9 14th March 2016, 08:05 AM

Drop O milk?

Had great intentions yesterday of cleaning down and sanding the frame but once I got to the garage the engine took my attention. I was hoping to get it to a rolling chassis stage first and foremost but after a bit of thinking I decided to get the engine sorted, then do the frame, pop the engine into the frame and then go from there to make life easier.

So my first time getting stuck into an engine. Rocker came off without issue, thankfully as well as Philips heads the bolts were hex as well, because there was no way they were coming out with a screwdriver. And of course, there's always one...out of 24 bolts, one was replaced with an Allen head that was touch and go for a bit. Cam chain tensioner off, could do with a good clean inside and out, everything looked in good nick on top anyway! Following a good guide for doing a z650 engine so marked the sprockets with Pistons 1&4 top dead centre for a good indication when putting it back together. The Allen heads on the top sprocket holder were both sheered on one side but they came off with a slightly bigger Allen bit in a screwdriver. Got the head off, Pistons heads are all seriously charred but after almost a year of sitting out in the elements everything is moving freely and as it should. The cylinder barrels aren't budging though. Was reading that the corrosion on the outside can effectively weld em onto the bottom end so that's a job for another day.

Cleaned up the frame afterwards so that's ready to be sanded down.

Had to order a new t piece. The original, while in great Nick both top and bottom yoke and steering stem, had a bolt snapped inside the clamp on the bottom yoke. Almost had it drilled and easy out but it was pulling the clamp apart to the point where it was going to crack so do €50 from GS bike breakers had one posted to cork. Everything as it should be, but a bit worn. All bolts included, just needs a tidy up. Stem has some rust but nothing that should matter. First time using GS bike breakers and would use again, messaging on fb, quick replies and next day delivery. Just needs bearings which I was planning on replacing on the old headstock anyway.

Photos to follow tonight!

Kingisabella · #10 14th March 2016, 08:04 PM

"old one"

"new one"

Theres always one..

My First Suzuki · #11 14th March 2016, 08:39 PM

Nice one

It's great to see a classic bike being given a new lease of life. Don't rush things & it will all work out in the end. My own project is running on for four years now but it's getting there

choppermann · #12 15th March 2016, 12:24 AM

nice job , right approach to doing it.
Best of luck going forward

Kingisabella · #13 15th March 2016, 07:16 AM

Kingisabella · #14 27th March 2016, 12:44 PM

After a morning and scraping dirt from the front of the engine, pulling and haulin, the barrells came off. Apparently on the front of the old japs bikes all the corrosion and dirt can build up and almost weld it on.

There was no play up & down on any of the rods, which is a good sign for the big end bearing? But if Im stripping down that far anyway, are they worth replacing while Im at it?

There does look to be a lot of sh*t built up down there though...partly from old oil its been sitting in for months outside, even though I had drained most of it, and then fresh grit and dirt from removing the barrells.

What am I looking for in relation to the pistons and rings? To my untrained eye they look and feel ok, no scoring or scratches that I can see or feel...

Barrells feel ok to the touch all round too..

Got the bucket and shims out but the numbers are worn away on most of the shims

Any advice on getting the valves out?

Or why two are black charred and two are grey charred?

2wheelsrbetter · #15 27th March 2016, 01:20 PM

you,ll need a valve spring commpressor tool to remove the valves,
i,ve a home made one you can borrow if you want .

-alan- · #16 27th March 2016, 02:12 PM

Tough old bird those by the look of things. Best of luck with the best of the rest of the teardown, and then the good bit - the rebuild :)

Originally Posted by Kingisabella

Or why two are black charred and two are grey charred?

Could be down to the mixture being on the rich side in the black ones - or simply more wear letting oil past the rings or the valve guides into the combustion chamber.

**chopper** · #17 27th March 2016, 02:39 PM

Id say there might be some 750 barrells and pistons here if ya need em

Kingisabella · #18 27th March 2016, 02:58 PM

Originally Posted by 2wheelsrbetter

you,ll need a valve spring commpressor tool to remove the valves,
i,ve a home made one you can borrow if you want .

Cheers

When the time comes Ill probably be in touch, sound for the offer

Originally Posted by -alan-

Could be down to the mixture being on the rich side in the black ones - or simply more wear letting oil past the rings or the valve guides into the combustion chamber.

Sound! Replacing the rings solve that problem?

Originally Posted by chopper

Id say there might be some 750 barrells and pistons here if ya need em

To be honst, first engine im into, I cant feel any signs of wear in the barrells. Is there anything visually thats indicative of their condition? What exactly pn the barrells and pistons should I be looking for as signs they need replacing or are damaged in anyway?

Any info at all is appreciated, everydays a school day!

**chopper** · #19 27th March 2016, 03:01 PM

Gimme a bell and ill explain how to check for wear .

-alan- · #20 27th March 2016, 03:19 PM

I'm no mechanic, but aside from the visuals you can get a feel for the overall wear fairly easily by measuring the end-gap in the rings.

http://www.youtube.com/watch?v=ch5ahHGyLIM

If it's on the large side, to see if it is wear the rings, you could either throw in a new one and remeasure the gap, or get some gear and start measuring the bore for wear. If a set of rings got you sorted that'd be a cheap enough fix - beyond that you'd probably be looking at an overbore, rings and pistons - and the costs start to mount.

That's when you have to start thinking seriously about whether you'd be better refurbishing what you've got, fitting some good s/h parts - or quietly selling off or parking the project in various boxes in the back of the shed until 'later' .. like most of us amateur/hobbyist types :)

edit..alternatively, as Chop suggests, talk to a pro earlier in the process rather than later and see what options he'd recommend before you start spending any hard earned readies on parts or tools