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 Post subject: New Project
 Post Posted: Tue Sep 23, 2014 12:07 pm 
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Victor Meldrew
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Location: Worcester
It's goodbye to the monkey bike, shortly to be advertised for sale.

I've bought myself a 42 year old Honda CL175, very similar (apart from exhaust) to the CB175 that I owned 42 years ago. Went to look it over this morning, a few problems noted, but not bad considering its age. US bike, one owner, 14K miles, last used in '79.

Image

Back in the day ..

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 Post subject: Re: New Project
 Post Posted: Mon Sep 29, 2014 11:16 am 
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Jesus ! Get a life !
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Oh wow that's fantastic Richard :D What a brilliant project. What's on your mind, to restore it to mint condition, or get it into great mechanical order and simply enjoy it?

Looks grrrreat! :angel

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 Post subject: Re: New Project
 Post Posted: Fri Oct 03, 2014 8:33 pm 
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Victor Meldrew
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Location: Worcester
Digital cameras lie !

Image

Considering that it's a '72 bike, chrome on the wheel rims is good, as are the alloy parts. Exhaust and mudguard chrome is not brilliant. I've stripped it right down now, came apart very easily, no seized fasteners.

Found a few more snags along the way, broken top yoke was the worst. I got very lucky and found a new old stock part for 25 quid, arrived this morning from a chap clearing out his garage. Replacement starter motor on its way from the States, costs more in carriage than the part does, couldn't find a UK one.

I'm going for CB175 style exhausts, down pipes and other bits arrived from David Silver the other day. Found a brilliant supplier of fasteners, Mr Megapack, complete set of external screws and nuts, case screws, axle nuts etc etc, 39 quid the lot, brilliant value.

A local company is going to blast, prime and powder coat the frame for 80 quid.

Loads more parts to sort out, but all going OK so far. Tank derusted and painted while the weather was still warm. I probably ought to do a build thread. Repaired that broken shock mount today, drilled and tapped it.

Edit - Rich, in answer to your question, it'll be a rolling rebuild, tidied up but definitely not show standard. Probably be better than my CB175 was, after I'd finished with it, 22k miles from new in 18 months, ridden every day.

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And then one day you find
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 Post subject: Re: New Project
 Post Posted: Sat Oct 04, 2014 4:21 pm 
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Hornet Lord
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Location: Newark on Trent
I didn't know they did a CL. But get that exhaust, shame that.

Keep us up to date with the (re)build and mind where you put the plate ...

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 Post subject: Re: New Project
 Post Posted: Sat Oct 04, 2014 6:18 pm 
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richard pitman wrote:
Image



That looks sweet ! The high level exhaust looks cool !

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 Post subject: Re: New Project
 Post Posted: Sun Oct 05, 2014 7:29 pm 
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Victor Meldrew
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Location: Worcester
Getting on with painting the fuel tank. I want to go for the CB175 look, even though the CL (Scrambler) tank is a different shape.

Rust removed.

Image

Zinc primer, followed by standard grey primer.

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Four coats of Honda Milano Red, flatted down between each coat, then masked off for a couple of coats of black. White pinstripes to follow, then a few coats of fuel proof lacquer.

See that brick wall ? I built that. 8o

Image

I'm aiming for something like this, 1973 CB175 tank

Image

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


Last edited by richard pitman on Sun Oct 05, 2014 7:39 pm, edited 1 time in total.

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 Post subject: Re: New Project
 Post Posted: Sun Oct 05, 2014 7:34 pm 
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Victor Meldrew
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Location: Worcester
New top yoke and repainted bottom yoke, stainless bolts fitted.

Image

This all started out with every intention of it being a rolling rebuild, but every time I find a rusty bit it seems a shame not to sort it out.

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 Post subject: Re: New Project
 Post Posted: Sun Oct 05, 2014 8:45 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
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At this rate its going to be finished before winter starts :clap

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 Post subject: Re: New Project
 Post Posted: Tue Oct 07, 2014 11:08 am 
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Victor Meldrew
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Location: Worcester
Frame, swing arm and centre stand went off to the powder coaters yesterday.

There is a small rust hole in a lower frame rail, which I was going to get sorted after I'd had the frame cleaned and coated. Arse about front I know, just couldn't stand the sight of the greasy dirty frame.

However, lad at the powder coaters told me that they also have a fabrication business, so they'll sort the welding out at the same time, result !

And another fluke find on Ebay. Remember, this is a bike that was never imported into the UK, so why folks over here should have new old stock is a bit of a mystery. The detachable bracket that bolts the prop stand to the frame is cracked and bent. I was going to get this welded up as well, then browsing ebay found a 'CL175 bracket', which turns out to be this very part, brand new, for about 7 quid.

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And then one day you find
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 Post subject: Re: New Project
 Post Posted: Tue Oct 07, 2014 11:34 am 
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Victor Meldrew
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Location: Worcester
On the flip side, bought a replacement starter motor from the US, couldn't find a UK one.

EDIT Found this today, probably would have fitted. :Bang

http://www.ebay.co.uk/itm/Starter-Motor-to-fit-Honda-125-Rebel-CM-CB-CMX-/181501216188?pt=UK_Motorcycle_Parts&hash=item2a4250c5bc

17 quid for the starter, bargain.

40 quid shipping fee, just had to grin and bear that.

And then today, package has arrived at Parcel Force, along with a charge for 'import VAT' and a 'Clearance fee', another 17 quid. Gits.

Just hope I don't find that I need to import any more bits, although bust kick starter is a likely candidate. :Bang

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And then one day you find
Ten years have got behind you
No one told you when to run
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 Post subject: Re: New Project
 Post Posted: Tue Oct 07, 2014 4:14 pm 
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Victor Meldrew
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Location: Worcester
Just needs the fuel resistant lacquer now.

Just hope I don't bugger it up at that last stage.

Image

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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 Post subject: Re: New Project
 Post Posted: Tue Oct 07, 2014 4:18 pm 
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Victor Meldrew
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Location: Worcester
And this afternoon I took the gearbox apart, discovered why the kick start didn't work ...

Image

This little blighter. Need to find the rest of the fragments now. Whether I'll be able to source a new bit is anyones guess, not looking hopeful at the moment.

Image

But then, it's got an electric starter, so why worry ?

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And then one day you find
Ten years have got behind you
No one told you when to run
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 Post subject: Re: New Project
 Post Posted: Thu Oct 09, 2014 10:15 am 
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Hornet Lord
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Nice project Richard.
Do you think that's why it has been off the road?


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 Post subject: Re: New Project
 Post Posted: Thu Oct 09, 2014 1:29 pm 
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Johnny English

Joined: Thu Jul 06, 2006 2:34 pm
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Location: Somerset
Great project/work Richard :clap

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 Post subject: Re: New Project
 Post Posted: Thu Oct 09, 2014 5:48 pm 
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Victor Meldrew
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Location: Worcester
It's an odd one, this.

The bottom half of the engine was untouched, virgin case screws etc, which all came out easily with impact driver. Apart that broken cog ( found all the bits, reconstructed it, happy that nothing is lurking), gearbox looks like new. My digital photo suggests that it is rusty, it's an optical illusion, just a golden coating of oil. Clutch plates are unworn, actually slightly thicker than spec.

Top half is a different matter. Cam, rockers and rocker arms all look fine. Some muppet has had a go at the left hand cam bearing / tacho drive, screws in there all chewed up, bearing face doesn't look to clever.

Head and valves well coked up. One side leaks through the exhaust valve when combustion chamber filled with paraffin, so a good decoke and valve grind is indicated. Pistons crowns also well coked up, cleaned up easily with a brass brush.

Bores don't feel worn, no wear ridge. Haven't checked the rings yet, couldn't budge the cylinder last night. WD40 down the bores doesn't leak away, but brings up a lot of rust when crank rotated to TDC. At the worst, David Silver has 1mm OS piston kits available, just need a decent rebore specialist, take it out to 181cc, more power :lol

14K miles on the speedo, assuming it a) works, b) is original.

My guess is that kick start broke and bike was laid up. Maybe someone over there decided to restore it, then abandoned the idea, because a lot of the chassis bolts were loose, wheels had been cleaned up, layer of light oil over everything.

Anway, I've now sourced the 'unobtainable' gear box pinion, three times over. Got a complete assembly coming from the US, then I found a dealership in this country with a list of old new stock Honda parts, two of these gears in stock, ordered one from them this morning. As well as the one I'd previously ordered from MSP in Holland, although I expect they took my order but will then report 'part unavailable'.

Dunlop K82 tyres expected tomorrow, for that old school TT100 look.

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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 Post subject: Re: New Project
 Post Posted: Fri Oct 10, 2014 8:01 pm 
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Victor Meldrew
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Location: Worcester
Lacquer went on OK without pickling or lifting transfers. :Pray

Now to let it cure for a while before final cutting and polishing.

Image

K82 tyres arrived today. I'd forgotten what fun it was, wrestling with tyre levers and inner tubes. Amazed how heavy the chromed steel wheel rims are, we are spoilt with todays cast alloy wheels. I will wrestle with the rear wheel at the weekend.

For the old timers here, TT100 tread pattern on K82 tyres. Made in France, rubber feels 'stickier' than I remember.

Image

And finally, a gratuitous look at the pistons.

Image

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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 Post subject: Re: New Project
 Post Posted: Sat Oct 11, 2014 7:52 pm 
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Hornet Lord
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These were a very popular bike in the U.S. so parts should still be available for most stuff. Quite a few have been imported now.


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 Post subject: Re: New Project
 Post Posted: Thu Oct 16, 2014 5:37 pm 
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Victor Meldrew
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Location: Worcester
Shiny bits back from the powder coaters this afternoon.

120 quid to blast and coat frame, swing arm and centre stand, including welding up a rust hole in lower frame rail.

Image

Image

One problem. I'd masked off various bearing surfaces, and assumed that these bushes in the swing arm were metal, certainly felt hard enough.

Image

Turned out that they were rubber. :Bang Worse still, they are no longer available, and even if they were, it'd be the thick end of 50 quid for four. :eek

However, I've found some bronze bushes with the correct dimensions, for 17 quid for four, delivered.

Thank goodness for the internet:D

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And then one day you find
Ten years have got behind you
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 Post subject: Re: New Project
 Post Posted: Fri Oct 17, 2014 6:31 pm 
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John Travolta (Are you Dancin'?)

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If you was Steve you would be fitting grease nipples in those bushes too! :p

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 Post subject: Re: New Project
 Post Posted: Fri Oct 17, 2014 7:33 pm 
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Victor Meldrew
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Funny you should say that, the idea had occurred to me.

This bike already has a grease nipple on the clutch actuating mechanism.

Pity I chucked my grease gun away years away, never thought I'd need it again, days of Mini swivel joints and radius arm bearing long gone ..

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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 Post subject: Re: New Project
 Post Posted: Sat Oct 18, 2014 5:47 am 
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WOOF!
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Richard, I'm sure I still have a grease gun in the garage. I will have a look for it.

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 Post subject: Re: New Project
 Post Posted: Sun Oct 19, 2014 1:15 am 
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Hornet Lord
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The new bushes should sharpen the handling up as well :)


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 Post subject: Re: New Project
 Post Posted: Sun Oct 19, 2014 7:20 am 
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Needs to get out more!

Joined: Sat Dec 31, 2011 1:50 pm
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Location: Nelson Lancashire
nice job Richard, paint looks very good. Engine is usually bullet proof but looks like some one has been a bit ham-fisted with the kick starter. You should enjoy it out on the road.
We have raced its bigger brothers the CB350 K4 and CB 450 (late 60's version) for over twenty years. oldgit


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 Post subject: Re: New Project
 Post Posted: Sat Oct 25, 2014 8:00 pm 
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Victor Meldrew
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Back from a weeks hols away from bikes and computers. Looks like I missed the MotoGp race of the year, I have it recorded on the Sky box but not the same now I know the result, foolishly opened my MCN when I got in.

Bronze bushes have arrived, and look as though they'll be a perfect fit. Cam bearing has arrived from the US, waiting to be collected from sorting office (underpaid shipping fee :Bang ), and a package of sundry parts is on its way from the Netherlands (CMSNL).

Engine is going to need a rebore before I put it back together, some corrosion damage to bores, and rings rusted solid into pistons. I will get oversize pistons from David Silvers, but wondering who to trust with the machining ? Local car engine place has been recommended (Malvern Rebores) but I wonder if they can do it to Honda standard ?

And there's a classic bike show and autojumble at Malvern tomorrow, will try to attend that.

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And then one day you find
Ten years have got behind you
No one told you when to run
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 Post subject: Re: New Project
 Post Posted: Wed Oct 29, 2014 9:05 pm 
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Victor Meldrew
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A bit more progress today, although nothing goes as simply as expected.

The bushes were a perfect fit, bearing on the swingarm spindle was a nice sliding fit.

Image

Until I pressed the bushes into the swing arm. I then had to ream them out, using a 20mm blacksmiths HSS bit, to get back to that nice sliding fit.

Image

And then the shoulders on the bushes were too thick, so that the spindle would clamp up onto the bronze bushes rather than onto the ends of the bearing sleeves. So I had to file them down until it all fitted as intended.

Image

I've visited a few local hardware places in the course of the above. Screwfix are consistently excellent, and incredibly cheap for A2 stainless nuts bolts and washer, packs of 100 for a couple of quid. Toolstation for the 20mm bit, hopeless. Website showed it in stock locally, so I 'clicked and collect', only to find that they expected me to wait two days for bit to be delivered to store. :Bang So I bought the one they had on the shelf, then had to go back two days later to get a refund on the bit ordered on line. Ridiculous. And then they wanted my 'photo ID', whatever that is. I don't have any. :Bang

And finally Machine Mart, had to pop in for some more files, mine had seen better days. I was tempted to ask for a b*****d file, just to see it the counter guy would retort, 'Yes, and we have some f*****g spanners as well ...

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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 Post subject: Re: New Project
 Post Posted: Thu Oct 30, 2014 11:31 am 
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Hornet Lord
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Screwfix, Tool station and Machinemart my you have been busy. why they could not just cancel your order when you were there I do not know!


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 Post subject: Re: New Project
 Post Posted: Thu Oct 30, 2014 12:25 pm 
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Victor Meldrew
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Location: Worcester
Tool Station will need to get their act together if they hope to compete with Screwfix.

Whilst I was at TS, a lady came into to buy some 'two inch woodscrews'. At first, the counter droid denied that they sold them. Then, had to ask colleague what 'two inches' was in millimetres. Then tried to sell the poor woman some 'Torx screws, they are the best ones'. Didn't think to ask whether the customer had appropriate driver bits or hand tool for these.

I bit my tongue and left, shaking my head in disbelief .....

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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 Post subject: Re: New Project
 Post Posted: Thu Oct 30, 2014 12:38 pm 
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Victor Meldrew
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Shocks, chain guard, centre stand and rear brake pedal fitted, fixings swapped for stainless.

Next job, fit new brake shoes, head stock and forks, get the chassis rolling.

Image

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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 Post subject: Re: New Project
 Post Posted: Thu Oct 30, 2014 7:15 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
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Coming along nicely :clap

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 Post subject: Re: New Project
 Post Posted: Fri Oct 31, 2014 7:28 pm 
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Victor Meldrew
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Location: Worcester
Took the cylinders, and one of the new 1mm OS pistons, to the rebore place. Guy had several other motorcycle cylinders waiting to be done, so hopeful that he knows what he is about. So my 174cc engine will grow to a massive 181cc !

Currently having a battle with the fork seals. Got the top covers off, but need a longer Allen head socket to get at the bolt in the bottom of the fork. Just hoping my impact driver will do the trick, otherwise looking at electric rattle guns ..

Image

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And then one day you find
Ten years have got behind you
No one told you when to run
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 Post subject: Re: New Project
 Post Posted: Fri Oct 31, 2014 8:35 pm 
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John Travolta (Are you Dancin'?)

Joined: Mon Aug 21, 2006 7:42 pm
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If you have not got an impact gun the trick is to crack the allen bolt off very quickly.

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 Post subject: Re: New Project
 Post Posted: Sun Nov 02, 2014 6:28 pm 
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Victor Meldrew
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This did the trick, 450nm of torque. I've never used one of these before, expect I'll find plenty of other uses for it, like sprocket nuts etc.

Image

Forks taken to bits, cleaned in paraffin then reassembled, waiting for new seals to arrive. I'm planning to use the old seals and some plastic waste pipe to drive them home.

Image

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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 Post subject: Re: New Project
 Post Posted: Sun Nov 02, 2014 7:50 pm 
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Knob Magnet
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oooh is that new? 8o 8o

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 Post subject: Re: New Project
 Post Posted: Sun Nov 02, 2014 11:54 pm 
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True Horneteer

Joined: Mon Jul 12, 2010 7:55 pm
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Location: Bexleyheath, Kent
How much is it costing for the rebore Richard, if you don't mind me asking? Considering getting it done to my zx9r and stick z1000 pistons in it, will take it out from 899cc to 953cc!

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 Post subject: Re: New Project
 Post Posted: Mon Nov 03, 2014 3:37 pm 
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Hornet Lord
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Nice new toy :)


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 Post subject: Re: New Project
 Post Posted: Mon Nov 03, 2014 9:16 pm 
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Victor Meldrew
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Joe, the oversize pistons, complete with rings, gudgeon pins and circlips, were £19.95 each, two of, obviously. Honda pistons not available, but these are Japanese made items, alleged to be high quality. Certainly look the same as the OEM ones.

Machining cost at Malvern rebores - they quoted me £50 plus vat for a twin, so presumably it'd be something less than a £100 for a four ?

Steve - yes, it was a distress purchase from Machine Mart, heavy old beast but it got the job done.

https://www.machinemart.co.uk/shop/product/details/clarke-cew1000-electric-impact-wrench

Got the fork seals fitted now, fork ready to go back on bike once I find my measuring cylinder to get the correct amount of fork oil in.

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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 Post subject: Re: New Project
 Post Posted: Mon Nov 03, 2014 9:31 pm 
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Victor Meldrew
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Location: Worcester
Engine cases rubbed down and painted with Halfords steel wheel paint, good match for original paint. Rest of the engine will be left bare aluminium, as standard. I saw a 400/4 at the recent Malvern show. Guy had sprayed the entire engine with silver paint, looked bloody awful, IMHO.

Image

Rear brake and hub cleaned out, new shoes fitted. Wheel bearings seem fine.

Image

Image

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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 Post subject: Re: New Project
 Post Posted: Tue Nov 04, 2014 11:35 am 
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John Travolta (Are you Dancin'?)

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Got one of those impact guns myself, bit big and bulky but does the job. Where did you get the extended allen key Richard?

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 Post subject: Re: New Project
 Post Posted: Tue Nov 04, 2014 1:01 pm 
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Victor Meldrew
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Location: Worcester
From Amazon. Probably Chinese stuff trading under a western sounding name, but it seems OK.

http://www.amazon.co.uk/BERGEN-Professional-Piece-Allen-Socket/dp/B006B3O43E/ref=sr_1_18?s=diy&ie=UTF8&qid=1415102509&sr=1-18&keywords=BERGEN+TOOLS

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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 Post subject: Re: New Project
 Post Posted: Tue Nov 04, 2014 1:23 pm 
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Victor Meldrew
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Location: Worcester
Front brake stripped and rebuilt.

Image

Image

Image

Forks in, chassis rolling. Now to sort the handle bars.

Image

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And then one day you find
Ten years have got behind you
No one told you when to run
You missed the starting gun


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