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Search results

  1. jdub6092

    Jdub goes there 1981 650e rebuild

    After searching far and wide on how to restore chrome, especially dull and hazy chrome, I realized that re-chroming is really the only answer if you want anything close to the original finish. Since I wasn't going there, I instead went with the multiple rounds of sanding with WD-40. From 320 up...
  2. jdub6092

    Jdub goes there 1981 650e rebuild

    Have been cleaning up the new head and taking a shot at grinding down the original. It has been a very slow process with several rounds of lapping compound to remove the absolute minimum amount of material, but I now have the cams spinning freely. I have been tempted to just start re-shimming...
  3. jdub6092

    Jdub goes there 1981 650e rebuild

    I did go ahead and purchase a used head with cams and caps as I anticipate removing the required amount of material from cam journals and caps is going to be a crapshoot. The mechanic I spoke to said it would likely require a flapper sanding disk to remove the required amount of material. Now I...
  4. jdub6092

    Mikuni 32mm CV carb volume

    I was planning on building a carb fuel gage by drilling a hole in a float bowl screw with epoxied nipple and clear hose. I still may, but the drill bit broke off inside the $9 screw and I've already wasted time trying to get it out. So I decided to try something different. I hooked up the carbs...
  5. jdub6092

    Jdub goes there 1981 650e rebuild

    Back after a 3 week tour of Eastern Europe. Was set up to purchase a new head on EBAY after making an agreement with the seller to delay the shipment. Then my small shoulder bag with wallet, cards, cash, drivers license, passport and spare phone was stolen in Lithuania. Included the credit card...
  6. jdub6092

    Jdub goes there 1981 650e rebuild

    There was one bolt hole that required welding and another couple where i attached a vice grip to see if i could remove the broken bolts. I scratched it up, but really just surface scratches and nothing too deep.. i think the extra material from the weld was the main reason he did it. Probably...
  7. jdub6092

    Jdub goes there 1981 650e rebuild

    Unfortunate, this guy had a reputation for quality work. He recommended a mechanic who said he has had success at using valve lapping compound and spinning the cams by hand. However, he said he hasn't had to grind off as much as .16mm before. Since I'm looking at a new head, I figured I'd give...
  8. jdub6092

    Jdub goes there 1981 650e rebuild

    Even if I could somehow hone the journal and cap bearings to freely spin the cams, I'd be looking at a full set of thinner shims and no guarantees. I can clearly see that the caps can rock to either side with the cams installed. I measured a 0.33mm gap when pressed down flush on one side, so I'm...
  9. jdub6092

    Jdub goes there 1981 650e rebuild

    I now think I know why I have binding on the camshafts. The machine guy I had repair the damaged valve cover bolt threads, said he decked the top of the head also because of scratches resulting from attempts to remove the broken bolts. I cleaned up the journal bearings and cap surfaces with wd40...
  10. jdub6092

    Jdub goes there 1981 650e rebuild

    I pulled out the valves and wanted to see how the camshafts turned without resistance. Well, turns out that the journals on both are binding. I cant budge them when the holders are snuggled down. 1/4 turn back on holder bolts and they do rotate, but the exhaust side is still a little sticky...
  11. jdub6092

    Jdub goes there 1981 650e rebuild

    I followed the manual except i counted out 20 link pins instead of 19. Bolted the holders down evenly, exhaust side first. Then intake cam allowing some slack. Then I installed the tensioner. Rotated the crank one turn until slack between cams was removed, but it isn't overly tight. Then I...
  12. jdub6092

    Jdub goes there 1981 650e rebuild

    Went with the above. Doesn't matter. Can't turn the crank with camshaft holders torqued down. It rotates when the holders are backed off a couple of turns. I knew there would be days like this.
  13. jdub6092

    Jdub goes there 1981 650e rebuild

    I think I answered my own question. The manual is not correct as it is listed as links 1-20 on the GS650G manual as well as several other models. The manual also doesn't seem to match the timing marks. It shows text that doesn't match the timing plate and then shows two different sides of the T...
  14. jdub6092

    Jdub goes there 1981 650e rebuild

    Thanks rphillips. I cranked down the holders at the synced position. Now I'm counting cam chain links and my manual says 19 link pins between the vertical arrows on the sprockets (link pin 1 lines up on the exhaust side and link pin 19 on the intake so actually only 18 links between as I read...
  15. jdub6092

    Jdub goes there 1981 650e rebuild

    Trying to get Cams installed. I noticed that the initial positions with arrows aligned per manual do not allow the journals to seat. There is a cam lobe that is just contacting a shim enough to raise the journal from the bearing surface. Appears to be the case on both cams. Is this normal?
  16. jdub6092

    Jdub goes there 1981 650e rebuild

    When waiting for parts or other engine building delays, I'm trying to keep busy polishing parts, touching up emblems, etc. Not sure I like the chromish appearance of the case covers. Any tips for making them look more stock in appearance?
  17. jdub6092

    Jdub goes there 1981 650e rebuild

    Next step was to measure the cam lobe heights. All of them are below service limits by 0.2 - 0.4 mm/.01"-.02" Is this a deal breaker for continuing or would I just expect less than optimal performance? I've found a used set of camshafts that reportedly came off a bike with < 13k and waiting for...
  18. jdub6092

    Jdub goes there 1981 650e rebuild

    Got the valves installed in the head and had some difficulty installing the buckets over the springs. Again learning that patience is the key, found that rocking them back and forth while very slowly pushing down at first is the key. Once they are squared up, they slide down easily with...
  19. jdub6092

    Jdub goes there 1981 650e rebuild

    More delays and learning experiences. Was able to get the cylinder installed on the pistons after trying several methods, forgetting to install the dowels, trashing a base gasket and lots of choice language. Eventually, I found that it was actually a lot easier to use the DIY piston holder...
  20. jdub6092

    Jdub goes there 1981 650e rebuild

    Thanks for the suggestion. I can see how bead grit could have gotten into the cam journal oil passages with no way out as I dont think the oil bolts were removed at the time. I didnt really see any grit come out, just some light color possibly from dried oil. should have done this before I...
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