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-   -   Hondo's 1983 CB1000 Custom Rejuvination (http://www.advrider.com/forums/showthread.php?t=556618)

Hondo 03-06-2010 06:57 AM

Hondo's 1983 CB1000 Custom Rejuvination
 
http://www.klrworld.com/HonPics/trip...v_08/cbczb.JPG

My 1983 CB1000C started burning some oil last year, and with approx 50,000 miles on it, it's time that I went "IN" to fix a few things-

The plan-

- Remove the engine
- Degrease it
- remove the head and cylinder, inspect, clean up, lap seats
- At a minimum, replace the valve guide seals, base & head gaskets
- look the cam chain & tensioner over
- replace parts as needed
- clean up the frame, inspect all wiring
- remove the swingarm and service all bushings
- paint the engine before install

Day 1

The before shot -

http://klrworld.com/HonPics/CB1KC/cbrba.JPG

Had to buy a floor jack for the job -

http://klrworld.com/HonPics/CB1KC/cbrbb.JPG

Down and dirty- getting those carbs out was a bitch -

http://klrworld.com/HonPics/CB1KC/cbrbc.JPG

The insulators between the head & carbs are as hard as nails, so they got ordered too.

Hondo 03-06-2010 06:58 AM

Day 2

Wow, what a beautiful day to work on the bike!

I went out to the shop with the kids and got the final mounts removed in preparation for the engine removal. Once I had it ready I called Beemer Pat- he was going to help me get the engine from the frame to the Jeep to the car wash and then to the bench.

After a few final grunts we got it out (balanced on the floor jack) -

http://klrworld.com/HonPics/CB1KC/cbrbd.JPG

We heaved it into the back of the Jeep and headed for the car wash. This right before we lifted it out and sat it on Pat's tall milk crate -

http://klrworld.com/HonPics/CB1KC/cbrbe.jpg

Pat got the initial honors -

http://klrworld.com/HonPics/CB1KC/cbrbf.JPG

Then we soaked it for a bit with Gunk & tire cleaner -

http://klrworld.com/HonPics/CB1KC/cbrbg.jpg

I was a scrubbin' fool (the temp was dropping rapidly) -

http://klrworld.com/HonPics/CB1KC/cbrbh.jpg

Then the massive pressure washing campaign began. Pat took these pics -

http://klrworld.com/HonPics/CB1KC/cbrbi.jpg

A little here....

http://klrworld.com/HonPics/CB1KC/cbrbj.jpg

a little under there...

http://klrworld.com/HonPics/CB1KC/cbrbk.jpg

I was soaked, cold and happy with the progress -

http://klrworld.com/HonPics/CB1KC/cbrbl.jpg

We put the engine back in the Jeep and headed to the shop.

What have I gotten myself into! :lol3

http://klrworld.com/HonPics/CB1KC/cbrbm.jpg

We got the engine out of the Jeep, onto the floor jack and moved it across the shop to the bench -

http://klrworld.com/HonPics/CB1KC/cbrbn.JPG

Tomorrow I begin the teardown -

http://klrworld.com/HonPics/CB1KC/cbrbo.JPG

Thanks for all of your help today Pat!
:thumbup

Hondo 03-06-2010 06:58 AM

Day 3 on the CB1KC

- removed the valve cover and started disassembling the valvetrain- hey, I better take a pic -

http://klrworld.com/HonPics/CB1KC/cbrbp.JPG

I removed the cams and all of the bearings looked great -

http://klrworld.com/HonPics/CB1KC/cbrbq.JPG

Old blue jeans legs protect the cams nicely...

http://klrworld.com/HonPics/CB1KC/cbrbr.JPG

Then I removed the lifters and set them into egg crates that I was saving...

http://klrworld.com/HonPics/CB1KC/cbrbs.JPG

With a little persuasion from a dead blow hammer I removed the head. one corner was chipped from a previous service -

http://klrworld.com/HonPics/CB1KC/cbrbt.JPG

I set the head to the side and started removing the carbon from the top of the pistons before I removed the cylinder assy. This is what most of the piston tops looked like (though the valve recesses in the other pistons were almost completely full of carbon) -

http://klrworld.com/HonPics/CB1KC/cbrbu.JPG

All cleaned up -

http://klrworld.com/HonPics/CB1KC/cbrbv.JPG

Compared to it's neighbor -

http://klrworld.com/HonPics/CB1KC/cbrbw.JPG

All cleaned up -

http://klrworld.com/HonPics/CB1KC/cbrbx.JPG

Then I removed the cylinder assy and sat it aside. Time to disassemble the head.

I measured each spring for size and all were good. Then I set them into another crate -

http://klrworld.com/HonPics/CB1KC/cbrby.JPG

I organized the valves on a box. They will all need some cleanup, but look really good -

http://klrworld.com/HonPics/CB1KC/cbrbz.JPG

Next was to decarbonize the combustion chambers and as much of the ports as possible. I used a series of small wire wheels in my dremmel too. I hooked the sho vac hose up to the ports to keep things tidy -

http://klrworld.com/HonPics/CB1KC/cbrbz1.JPG

The chamber on the left is the before, the right the after -

http://klrworld.com/HonPics/CB1KC/cbrbz2.JPG

Once I got that done I called it a day -

http://klrworld.com/HonPics/CB1KC/cbrbz3.JPG

Hondo 03-06-2010 06:59 AM

Day 4 - Clean and "Lean"

I started day 3 with a quest to buy a grinder & wire wheel, as that was what I needed to clean the valves of their 27 years of build up. So I picked this one up at Harbor Freight -

http://klrworld.com/HonPics/CB1KC/cbrbz4.JPG

The wire wheel did a great job on the valves and the light was a definite plus.

Before-

http://klrworld.com/HonPics/CB1KC/cbrbz7.JPG

After -

http://klrworld.com/HonPics/CB1KC/cbrbz8.JPG

It took me a good hour to get all 16 valves cleaned up.

Then I went to the car wash and pressure cleaned a bunch of parts. The oil cooler lines (braided hose wrapped in a spring) were really nasty, and I ended up cleaning them with Goop hand cleaner - it worked great! After that I scrubbed 'em down with dish washing soap & hot water.

The trip to the car wash got me thinkin' about the frame- I really wanted to bring it to the wash and pressure wash it too, but I had no way to get it there. It has a lot of built up sludge from an oil leak- here a pic of the coils before I removed them -

http://klrworld.com/HonPics/CB1KC/cbrbz9.JPG

So I left Beemer Pat a message, hoping he'd be able to swing by with his pickup truck.

Well, Pat had other ideas -

http://klrworld.com/HonPics/CB1KC/cbrbz9a.JPG

So Pat towed me & my "Lean Machine" up to the car wash. We drew a lot of looks, and a bunch of kids stopped dead in their tracks to watch us ride by. :lol3

We pulled into the wash right next to a gal who was cleaning up her 1965 Dodge Dart, complete with a red emergency light on the top -

http://klrworld.com/HonPics/CB1KC/cbrbz9b.JPG

Clean it up!

http://klrworld.com/HonPics/CB1KC/cbrbz9c.JPG

Cool car wash pic -

http://klrworld.com/HonPics/CB1KC/cbrbz9d.JPG

While I was workin' Pat made freinds with our future photographer -

http://klrworld.com/HonPics/CB1KC/cbrbz9e.JPG

She was more than happy to document our little urban adventure -

http://klrworld.com/HonPics/CB1KC/cbrbz9f.JPG

When we got back I decided to remove the pistons from the engine due to the amount of build up-

http://klrworld.com/HonPics/CB1KC/cbrbz9g.JPG

27 years on these ...

http://klrworld.com/HonPics/CB1KC/cbrbz9i.jpg

I set the pistons aside and decided to seal up the block so that I could clean the crud off of the studs safely and to prep the block for paint-

http://klrworld.com/HonPics/CB1KC/cbrbz9j.JPG

After That I decided to call it a day -

notarex 03-06-2010 03:28 PM

:thumb

XS500RUS 03-06-2010 03:50 PM

Very cool thread, I love to see an older machine brought back to brand new condition.

I was almost expecting to see another "Hey I'm gonna hack it apart, put clubmans on it, paint it flat black and call it a cafe" sort of thread:puke1 . Good to see a bit of history preserved. Did the Cb1000s have the dual range gearboxes like the Cb900s? What kind of fuel economy does it get? Lovely looking bike, I'm really coming around to the 'custom' look as of late.

MayerMR 03-06-2010 03:56 PM

Great thread and great progress! Did you buy that bike new?

Bigger Al 03-06-2010 05:28 PM

Nice work so far, Hondo!:clap Should be a real beauty when you're done.:freaky

Hondo 03-06-2010 07:02 PM

Quote:

Originally Posted by XS500RUS
Very cool thread, I love to see an older machine brought back to brand new condition.

I was almost expecting to see another "Hey I'm gonna hack it apart, put clubmans on it, paint it flat black and call it a cafe" sort of thread:puke1 . Good to see a bit of history preserved. Did the Cb1000s have the dual range gearboxes like the Cb900s? What kind of fuel economy does it get? Lovely looking bike, I'm really coming around to the 'custom' look as of late.

Yep, it has a 5 speed gear box & a Hi & Low range (city/highway) - works great.

I usually get only around 35 mpg.

Hondo 03-06-2010 07:03 PM

Quote:

Originally Posted by MayerMR
Great thread and great progress! Did you buy that bike new?

No, I bought it with 45K miles on it in the fall of 2008.

dorkpunch 03-06-2010 07:42 PM

This oughta be fun! I sold my 900C last summer... Still kickin myself for that one. I had 10 other bikes on the trailer, and one of them wouldnt fit, and unfortunately the 900 sold first. Fun bikes! Looks like a great project.

kawasakifreak77 03-07-2010 08:59 AM

Neat to see a regular 'ole rebuild! Question though.... What's the deal with the dual shifter looking things on the left side of the case?

I'm guessing that was a stupid question but I can always fall back on my youth for not knowing anything, lol!

dorkpunch 03-07-2010 09:39 AM

the Custom has a Hi/Low range- you have 5 gears in low and 5 gears in high, shift it on the fly. I rode mine like a six speed- 1 thru 5 and then click it into high for "sixth". Really a fun bike.

m98 03-07-2010 03:26 PM

Hondo, really nice write up. :clap

Paul

Hondo 03-07-2010 03:56 PM

Day 5 - Carb Teardown

I decided to go through the carbs and clean them up - they really were pretty nasty.

I bought 4 food bins and a 24 compartment box to keep things organized -

http://klrworld.com/HonPics/CB1KC/cb1a.JPG

I also bought a plastic bin that I could soak the carb bank in. Behind it is the 3 bottles of Pinesol that I will be soaking the disassembled carbs in -

http://klrworld.com/HonPics/CB1KC/cb1b.JPG

So I got busy - float bowls off, floats out, getting ready to remove the jets -

http://klrworld.com/HonPics/CB1KC/cb1c.JPG

The bottom side is almost done (pilot screws to go)-

http://klrworld.com/HonPics/CB1KC/cb1d.JPG

I then removed the slides, needles & such and wiped off as much of the gunk as I could (sorry , no pics.

Then I poured the Pinesol into the bin and put the carb assy in to soak -

http://klrworld.com/HonPics/CB1KC/cb1e.JPG

They're in there for at least 24 hours, maybe longer -

http://klrworld.com/HonPics/CB1KC/cb1f.JPG

Jets, floats and other goodies awaiting their turn at a detailed cleaning -

http://klrworld.com/HonPics/CB1KC/cb1g.JPG

I'll get to the rest tomorrow -

http://klrworld.com/HonPics/CB1KC/cb1h.JPG


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