All 650Fs Honda CB650F upgrade/maintenance log

[enshiu]

A good working tipover sensor installed

 

[enshiu]

To do:
- brake hoses (rear only)
- remap to 70kw+
- Michelin road 6 (rear)
- swapping out steering protection bar for a smaller one

- install smaller steering bar




Things done:
- fan fuse broke 02-04-2023
- throttle cable adjustment 02-04-2023
- oil change and filter at 130726km 02-04-2023
- rad cap changed 02-04-2023
- Headlight and rear licence plate light modded 04-04-2023
- front indicator and relay mod 05-04-2023
- rear light replaced 06-06-2023
- Rattle at 4k at the clutch housing > chain 12-08-2023
- Main engine cam chain needs replacement 12-08-2023 incl sprockets and chain guide
- white smoke at cold start and disappears > pcv cleanup and thermostat 12-08-2023
- exhaust leak due age > akrapovic exhaust
- air filter 12-08-2023 > BMC
- spark plugs 12-08-2023 CR9EHIX-9
- thermostat 12-08-2023
- coolant bs6580 12-08-2023
- front fork seals and oil 20-08-2023
- radiator protector and chain guide rubber 03-09-2023
- gear indicator 28-09-2023
- horn replaced and gear indicator 05-10-2023
- Michelin road 6 front tyre new 10-11-2023
- Rear indicators also replaced with OEM LED 12-12-2023
- tipover sensor replaced 26-04-2024
- engine out 25-04-2024
- engine parts transfer to new engine 26-04-2024
- parts cleaning and new gaskets where needed 26-04-2024
- MKK inlets installed 02-05-2024
- Engine back in again 02-05-2024
- used shifter linkage and pin installed without a lot play 02-05-2024
- engine swap to 2019 05-05-2024
- relocating tank vents 05-05-2024
- relocating coolant expansion tank for easier access 05-05-2024
- installing used throttle cable 05-05-2024

 

[enshiu]

So far so good.

Used 4 hands and 2 jacks to get the engine back to its home:

Maybe use the gear sensor to install a non rpm gear indicator.

I got the engine in.

- all coolant hoses fit.
- all coolant steel connections fit
- all intake rubbers fit
- all spark plug cables fit they are different spark plugs but, the cables fit
- EOP fits
- ECT fits
- CKP fits
- alternator not sure but, it came without one so put the old one over
- all coolant gasket fits
- starter fits
- TB fits
- clutch cable fits
- AIS fits
- exhaust fits
- VSS fits
- engine hangers fit

Need to redo:

- Neutral switch (2019 does have gear indicator) wiring only redo (LG wire)
- gear shifter stabiliser

 

[enshiu]

sorted

 

[miweber929]

Engine starts, Missing clutch and housing does the old type fit?

Both SHOULD fit, color seems to be the only difference. But at that mileage there should be fairly significant wear in the basket and plates, you may want to replace with a used basket.

 

[enshiu]

It has a clutch inside but, it rattles. Only 3250mls/5000km

 

[Cláudio Nogueira]

So far so good.

Used 4 hands and 2 jacks to get the engine back to its home:

Maybe use the gear sensor to install a non rpm gear indicator.

I got the engine in.

- all coolant hoses fit.
- all coolant steel connections fit
- all intake rubbers fit
- all spark plug cables fit they are different spark plugs but, the cables fit
- EOP fits
- ECT fits
- CKP fits
- alternator not sure but, it came without one so put the old one over
- all coolant gasket fits
- starter fits
- TB fits
- clutch cable fits
- AIS fits
- exhaust fits
- VSS fits
- engine hangers fit

Need to redo:

- Neutral switch (2019 does have gear indicator) wiring only redo (LG wire)
- gear shifter stabiliser

Great progression. Is there a list of "no fits?

 

[enshiu]

see reaction. Need to wait on a second hand neutral indicator

 

[enshiu]

Bike finished. Only need to wait on neutral sensor and remap

 

[enshiu]

So I have these sprockets on my CB650F for a 520 chain conversion

 

[Cláudio Nogueira]

So I have these sprockets on my CB650F for a 520 chain conversion

Why downgrade from 525 to 520?! Any special reason?
520 might suffer accelerated wear due to be less strong. Just guessing...

 

[Brammers]

A small weight saving can in theory lead to better handling. (unsprung weight).

Not really worth it IMHO. I'd rather have a correctly spec'd heavy duty chain.

J

 

[enshiu]

Its ok, another guy runs this chain after 30000km on the same bike no play on the chain.

Got my neutral switch in:

 

[enshiu]

To do:
- brake hoses (rear only)
- remap to 70kw+
- Michelin road 6 (rear)





Things done:
- fan fuse broke 02-04-2023
- throttle cable adjustment 02-04-2023
- oil change and filter at 130726km 02-04-2023
- rad cap changed 02-04-2023
- Headlight and rear licence plate light modded 04-04-2023
- front indicator and relay mod 05-04-2023
- rear light replaced 06-06-2023
- Rattle at 4k at the clutch housing > chain 12-08-2023
- Main engine cam chain needs replacement 12-08-2023 incl sprockets and chain guide
- white smoke at cold start and disappears > pcv cleanup and thermostat 12-08-2023
- exhaust leak due age > akrapovic exhaust
- air filter 12-08-2023 > BMC
- spark plugs 12-08-2023 CR9EHIX-9
- thermostat 12-08-2023
- coolant bs6580 12-08-2023
- front fork seals and oil 20-08-2023
- radiator protector and chain guide rubber 03-09-2023
- gear indicator 28-09-2023
- horn replaced and gear indicator 05-10-2023
- Michelin road 6 front tyre new 10-11-2023
- Rear indicators also replaced with OEM LED 12-12-2023
- tipover sensor replaced 26-04-2024
- engine out 25-04-2024
- engine parts transfer to new engine 26-04-2024
- parts cleaning and new gaskets where needed 26-04-2024
- MKK inlets installed 02-05-2024
- Engine back in again 02-05-2024
- used shifter linkage and pin installed without a lot play 02-05-2024
- engine swap to 2019 05-05-2024
- relocating tank vents 05-05-2024
- relocating coolant expansion tank for easier access 05-05-2024
- installing used throttle cable 05-05-2024
- swapping out steering protection bar for a smaller one 03-06-2024
- install smaller steering bar 03-06-2024
- install neutral gear switch 05-06-2024
- install gear shifter stabilizer 05-06-2024




Its very busy at the workshop I got today 90min to finish the small bits.

Rear brake hose I will install in the winter.

 

[JDude]

After changing my original chain (surprise, metal part of my tie down strap wasn’t popular when it went through) I would have no issue using a 520. I think the 525 is over engineered especially when using traction control. After measuring the stretch on the original chain, it was less than 1/4 inch for over 20k km of distance, but to each their own. I’ve really enjoyed your build and updates!

 

[FogDucker]

Ok, kind of what figured. I see there is a middle mounting point otherwise they’d put a lot of strain on the handlebars and they’d bend fairly easily depending on the bar. So you chose to run them? Kind of a “slider” thing I bet.

What they looked like in my head are something you’d use if you wanted to do crowd control, like in a zombie or Max Max futuristic style of movie, lol!!!

Crowd Control!! hahahaha

 

[FogDucker]

Front fork seals replaced, rear light upgraded, fuel hose between tank and injector rail and some small gaskets:

to do: removing the handle bar guard or whatever? my eyes man! my eyes....

 

[enshiu]

No, Never mind.

It pulls crazy with a 520 chain 15/41 sprocket

oem is 17/42

 

[enshiu]

Waiting on remap

 

[bwright00]

No, Never mind.

It pulls crazy with a 520 chain 15/41 sprocket

oem is 17/42

What rpm are you sitting at when going 65 mph/105kph? I want the quicker accel with different sprockets, I don’t care to have a high top speed, but I also don’t want to ruin my fuel consumption due to higher engine rpm when cruising