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Search results

  1. jdub6092

    Jdub goes there 1981 650e rebuild

    Thankfully didn't have to remove it. One note to add: After backing off the setscrew, hold it in place while tightenening the lock nut.
  2. jdub6092

    Jdub goes there 1981 650e rebuild

    I untightened the tensioner lock nut and the slack went away. I can see that the shaft screw tightened right along with the nut. DOH! Should have been intuitive. Timing is still good, so no tooth jumping ocurred. Very little room to work, so will need to dance with screw and nut, until the...
  3. jdub6092

    Jdub goes there 1981 650e rebuild

    Turns out that the cam chain goes from extremely taught to jumping a tooth or just loose. That's the click sound. I measured the links and it is well within specs. That had to be an incredible amount of force on the chain at higher revs. It didn't do this when I rotated manually many times. I...
  4. jdub6092

    Jdub goes there 1981 650e rebuild

    I think for sure it is something to do with the cams. I can now hear a slower click-click while it's cranking.
  5. jdub6092

    Jdub goes there 1981 650e rebuild

    Sorry, I forgot to make it public. Should work now.
  6. jdub6092

    Jdub goes there 1981 650e rebuild

    I haven't put the rubber dampers on the engine. Wondering if that might help.
  7. jdub6092

    Jdub goes there 1981 650e rebuild

    https://www.facebook.com/share/v/14Z6fMgwuf/?mibextid=qi2Omg I'm not an active facebook user, but wanted to share a video to see if anyone can recognize this sound.
  8. jdub6092

    Jdub goes there 1981 650e rebuild

    I attempted to start the bike last night. Got the oil circulating, checked compression (150,150,140,145), checked spark and then hooked up the tank. Nothing happened. Tried for about an hour. Found one of the not replaced spark caps fell apart when I pulled the plug out. Replaced it with another...
  9. jdub6092

    Jdub goes there 1981 650e rebuild

    Getting there. At least cosmetically.
  10. jdub6092

    Jdub goes there 1981 650e rebuild

    Put new OEM plug caps on order. Apparently NGK has discontinued these over a year ago and they will be very hard to find in the near future, especially the 120? long type. All that remains before attempting to start is repair of a broken exhaust clamp that Ive put off since the beginning of...
  11. jdub6092

    Carb-airbox boots won't stay on?

    I just got done doing this for the third time. The first time took nearly all day and I still may have had a leak. Just recently did rounds two and three and it went fairly quick, so I'll share what worked for me. Obviously, you need to remove the battery holder, then loosely attach the screws...
  12. jdub6092

    Jdub goes there 1981 650e rebuild

    Was hoping to attempt a start today, but did a last few checks. Found 35 kohm resistance between #1&#4 spark plug caps which is in spec. Then found an open circuit between #2&#3. Pulled off the caps and found one to be bad. Then measured across the two wires and got about 14 kohm coil...
  13. jdub6092

    Jdub goes there 1981 650e rebuild

    I moved the gas and vent hoses on the other side of the rail. Not that it matters, but because two sets of photos in the sevice manual show it that way. After four rounds, including thread repair, I finished shimming the valves. Results as follows: #1 exhaust: 2.50 - 0.05 #2 exhaust: 2.45 -...
  14. jdub6092

    Jdub goes there 1981 650e rebuild

    I'm getting close to firing this thing up for the first time in over a year. Made the bonehead mistake of installing the carbs and airbox without installing the fuel and vent lines first This was one of the most difficult jobs that I previously did due to the tight spacing. However, using a...
  15. jdub6092

    Jdub goes there 1981 650e rebuild

    Some good things have come from my head dilemma. First I realized that the manual was correct as far as the cam chain links. It actually is 19 link spacing even though the intake cam sprocket arrow does not point straight up. Every bike I researched from the era, including the 650g and gl that...
  16. jdub6092

    Jdub goes there 1981 650e rebuild

    Thanks for the tip Dom. I was amazed at what a fine wire wheel and some polish and buffing could do a dull piece of dull aluminum. Ill give it a shot.
  17. jdub6092

    Shim kits for valves?

    Thanks for the great tip Rijko. I knew the shims would be smaller due to my machist's blunder in decking the top of the head. I tried a trick to save the head and lapped the cam bearings and journals to lower the camshafts by up to 0.1 mm to allow the cams to spin without binding. I am able to...
  18. jdub6092

    Shim kits for valves?

    Need help re-shimming my valves. I had sizes from 2.55 to 2.70 mm. I moved a 2.55 and 2.55X to locations where there were 2.70's. Cannot fit a 0.04 feeler into either, so I will need a kit with 2.50 and below. It looks like kits don't come in specific sizes from a cursory search. What is the...
  19. jdub6092

    1981 gs650g project

    I'm certainly not one of the experts here, but am currently rebuilding the chain drive model of that same bike and have learned a lot from this forum and pretty much know every component down to the screws and bolts. If you have any doubts about anything, consult the manual, search for the...
  20. jdub6092

    Jdub goes there 1981 650e rebuild

    I have decided to give the original head a try for a couple of reasons. I was able to get the cams to move freely after grinding the journals, bearings and caps down with valve grinding compound. I was quite surprised that the measurements between bearing and journal diameters were so...
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