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Hey everyone, I apologize for not posting recently. My wife had a baby and work has been crazy. I'd like to start putting everything back together soon. I let me buddy use my grinder while I was away and when I got back I saw a bunch of tiny metal dust around my parts. He didn't think to...

Good question. I originally glass bead blasted the engine, and this is where I ran into problems with the glass getting embedded. I then found a used engine on craigslist for cheap, so instead of spending a ton of time on the original engine that I messed up glass beading, I tore the 2nd engine...

Thanks for the info, definitely good to know. I still have the pistons, jugs, crank, cases and crank. I was thinking maybe going for an all out build on these when I have the cash. Rephase the crank, 750 top end, all of the other good stuff. But that could be awhile from now.

Thanks 5twins. Good to know I can re-use the old ones. I actually took the starter motor out, so I guess I don't need the o-ring :). My thinking was better to have it and not need it then not have it when I do need it. Also good to know about the topend bolts. I was thinking I should replace all...

Hi Guys, One more question before I take a break to start putting this thing back together. I'm trying to come up with a list of parts I need to buy for the rebuild. I'm mainly looking at gaskets/fasteners, etc. I might end up purchasing bigger parts (clutch plates, etc.) later, but I for now...

Thanks a bunch! I'll put my order in today and hopefully have everything ready for next week to start building the engine back up.

It looks like they are two different types of washers though. See the screen grab below. Now that I'm reading the description better it looks like the top brass ones are for the heads and the copper washers are for the other top fasteners. Thanks!

Sounds great. I'll take a stab at it and see if I can make them all good again. We have a little steam cleaner with a jet nozzle that we got suckered into buying at a home show so I'll try to put it to good use :)

So now I am ready to start putting everything back together. I purchased an athena gasket kit and a full seal kit. I'm also going to purchase complete top and bottom end fastener kits as well as you might as well have some shiny bolts on a nice clean engine. I just got the parts back from the...

While I had the head apart and getting cleaned I had the valve seats cleaned up and had intake and exhaust ported. When I put my fingers in there you could feel a really sharp edge it was definitely blocking the flow of air. We cleaned that up and now we should have some good air flow going in...

So after breaking everything down, putting all the parts into bags, labelling them and making sure everything was still there I ended up with a bench full of all the big parts. I took some time to split the cases. This actually took the longest out of everything. I carefully removed all the...

I also took a ton of photos of every step. I took photos from different angles, took photos before it was taken apart, during, and after to show as references. Again, this way I could see what it should look like going back together and what order the parts came off in. For example, here are 8...

So I don't think I'll give a step by step instruction on how I disassembled the motor. I doubt many people want to see that and the manual does a good job of showing you how to do it. If anyone wants any details just shoot me a message and I'd by happy to show you what I did. The three things...

So I started tearing this engine down and I was happy with what I found. Pistons and jugs that were in great shape, and crank that was in spec and bearings that looked good. I used both my Haynes and Clymer books to break it down step by step. I was finding that there were some parts of the...

I've kept the cases just in case they can be salvagable. I started scouring the internet for new cases and I was coming up empty handed. There was a bunch of stuff on ebay but it was overpriced. I went to the local old motorcycle shop here and they had a super beat up engine that had literally...

So the engine was all apart, trans and crank out, etc., and I thought it was time for a good clean. I talked to some friends and looked on here and it looked like it would be safe to glass bead the engine. So I took it to my local blaster and put it in the cabinet and started blasting away. When...

Here's the jug completely scored. And the piston that came out of there So I was orginally thinking I would just bore out the cylinders and put some oversize pistons in there, easy fix! That was until I started getting into my crank and took a good look at the small end of the crank...

So here's my engine taken out of the bike. It had a Pamco system, Hugh's PMA, aftermarket oil filter, new valves and guides, and the crank had been rebuilt with new rods and bearings by previous owner.

Hi Everyone, I've "built" a few 650s over the last 10 years or so, but am no way an experienced builder when it comes to engines. Over the last few years I put together the bobber pictured below, and have had a lot of fun on it. I know the wheels/handlebars/stance are not set up for a go fast...

So the scotch brite worked great! Here's the race after a little rub down. Thanks again!