CB750F Project: Part VII

I finally made some progress.

After messing with paint for weeks,  I started on partial reassembly today.

First on the chopping block were the front forks. The seals did not leak, but since I had it apart, I decided to replace them anyway. And a good decision it was. The seals in there were probably the original set, and they were extremely hard. It took a few shots of PB Blaster and a warm cloth on the exterior, along with heavy prying to get them out. After that, I washed all parts with a solvent (I used brake cleaner, taking care not to damage O-rings and plastic rings), then blew out debris with compressed air, wiped everything clean, and reassembled. Damper-rod bolts received new copper washers, and a thin coat of RTV sealant.

I then reinstalled the centerstand in the frame, and proceeded with engine installation. I still have to do valves, take off side covers for polishing, and a few other things, but working on the engine will be easier if it is in the frame instead of laying on the floor. Engine installation is usually a 2-3 men job, but since the frame was completely stripped, I was able to position the engine on a piece of foam insulation (2" board, to prevent damage), set the approximate angle at which it rests in the frame, and slide the frame over/under it. It took a lot of careful wiggling and moving around, but I was able to set it just right. I then attached the engine to the frame and torqued all fasteners to the rights specs. With front forks installed, it was easy to lift the rear and kick the centerstand down, thus resting the frame with engine in it in the upright position.

To prevent the frame from falling forward while working on the rear, I temporarily reinstalled the front wheel. This allows the frame to stand up on the centerstand without falling over.

I then reinstalled the rear swingarm, with fresh lube of course. At this point -- engine mounted, steering head installed, front forks fixed and installed, swingarm installed, the rear shocks installed -- I attached the new handlebars and the fuse block.

Being nosy, I mocked up the tank and the tail section, which in turn allowed me to put the seatpan in place, and mark where I need to fabricate its fastening system. At the same time, I marked where to cut the seat foam, and next week I'll start on completing the seat.