Topic: BabyHawk.. the CB160 build.

[jas67]

Have a couple of questions.

Working on the front forks. The parts diagram does not show lower fork bolts and copper washer. Mine has them. 

The parts diagram you are looking at is probably for the earlier steel lowers, which were painted the same color as the rest of the bike.
The silver-painted ones are aluminum, and have some differences, such as different fender mounting hole locations.   The bosses for the fender mounting holes are centered on the steel lowers, and offset on the aluminum ones -- something to keep in mind if you replace fenders.

[toytuff]

As with any older motorcycle it's hard to know what you have. Titled as a 1969, wiring harness 1965.

I'm looking at the diagram and yes, hard to figure out. If you look at number 14 this is what I am trying to remove from number 5.

It almost looks like it is threaded on but once again, it's not the right diagram compared to what I have. Unless this cover removes new fork seals can not be replaced. I have cleaned the best I could given the depth and I can see the snap ring that holds the seal. This would be item 6. Footnote: There are two (2) items labeled number 6 both being different.

Saga continues. Progress slow. Dust seals removed but the chrome cover will not move. I have soaked in PB Blaster and heated. I tried to wish it off but that did not work.

tt 

[toytuff]

OK, a determination has now been made. I have fought these covers on other builds.

I did get the dust seals out.



Soaked the forks and cleaned the top of seals best I could.



Then I looked at the spare CB160. (nice to have two huh?)

As I suspected they slide off. In this case they do not slide off. On there pretty deep I might add. Someone was in the fork area at one point.



A long way to go. Around 30mm.



Saga continues. Out of ideas for today.

tt

[jas67]

As with any older motorcycle it's hard to know what you have. Titled as a 1969, wiring harness 1965.

I have two CB160's and one CL160, all three titled as '67.  I haven't checked for a date on the wiring harnesses.
The two CB160's both have the earlier steel lowers, and the CL160 the aluminum ones you have.
It is possible that your forks were changed out for the later style at some point.

[jas67]

OK, here are your two different fork diagrams.    The CL uses different fork ears, and gators instead of the metal covers, but, pay particular attention to the lowers.

The lowers shown on the later CL fork are the same as the lowers you have pictured.

1965 "CB160" -- shows the steel lowers with the fender mount bosses in in the center:
http://www.hondabikes.com/fiche_section_detail.asp?section=2559095&category=Motorcycles&make=Honda&year=1965&fveh=132814
Big Image: http://farm8.staticflickr.com/7431/10964159016_d767f8e353_o.gif


1966 "CL160" -- snows the aluminum lowers with the fender mount bosses offset as your fork is:
http://www.hondabikes.com/fiche_section_detail.asp?section=2559099&category=Motorcycles&make=Honda&year=1966&fveh=132815
Big Image: http://farm6.staticflickr.com/5538/10964158736_1ba0820664_o.gif

[toytuff]

That may be but neither one shows a bolt in the bottom of lower fork.

tt

[toytuff]

My Lord that was hard! Not looking forward to the right side. 



Both wheels are finished. 



Fork is not coming apart. Something is holding it. I'm thinking it's the bushing. Going to attempt removing the fork seal and see what's going on. They should pull apart but they are not. Fighting me all the way. 

tt

[MoMo]

A vague recollection but I think once the circlip ring is removed the entire fork tube assembly slides out.  The lower leg would be clamped in a vise while pulling the tube up like a slide hammer.  Not all that sure though...Larry

[RAFster122s]

Think you need a machinist to fab a pair of pullers that clamp arount tube but engage chome cover. Then a few good smacks on flange machinist made and Bob is your uncle...not assembled.

David

[toytuff]

Right cover came off easy. Lower fork bolt took a couple of hours. Drill and easy out. Nightmare.

Forks are apart. Larry was right, heat and beat.

tt

[toytuff]

Moving along on this project. All parts are cleaned, paint is done with the exception of the fork lowers. Still deciding which way to go. Waiting on carburetors and a rear tire which should be first of next week.

I got the forks to break free.

Left:



Right:



Removed the triple tree and counted 36 1/4" ball bearings. Check. Cleaned up parts.



Then the neck.



And partially assembled. Lock cleaned and lubed.





tt

[Greggo]

Looking great!

[jas67]

Looking great!

+1
 

[toytuff]

Thanks guys!

One bolt at a time. 

tt

[HondanutRider]

Looks great!  Don't forget to get those Thai parts.

[toytuff]

Looks great!  Don't forget to get those Thai parts.

Not on this one. 

tt

[Stev-o]

Hey tt, I know you didnt paint the frame but that looks too incredibly good to be original.
Any chance that has been repainted sometime in its life?

You are the BabyHawk man!

[volare71]

 

These little gems are gorgeous.  The less you do in changing the bike the better.  With clean bowls and good compression you might want to start her up.  If it doesn't fire up immediately a thorough carb cleaning is in order.
that tank is ripe for an electrolytic cleanout with washing soda and a strong battery charger.  Fill the tank with sodium carbonate (Arm and Hammer washing soda-not baking soda 1/2 cup to a tank of water and place the negaitve cathode in the tank and the positive anode connected to bare metal.  The rust will migrate from the inner tank to the cathode releasing rusty foam.  Overnight will do it.  I use a piece of rebar bent in an L shape for the cathode and insulate with plastic aerosol can lids and a peanut butter jar lid at the filler.  Works great and you won't need to paint sealer in the tank.  It will also spare the original paint.

[toytuff]

Hey tt, I know you didnt paint the frame but that looks too incredibly good to be original.
Any chance that has been repainted sometime in its life?

You are the BabyHawk man!

It's original Scarlet Red Steve. 

I work the magic! 

tt

[toytuff]

These little gems are gorgeous.  The less you do in changing the bike the better.  With clean bowls and good compression you might want to start her up.  If it doesn't fire up immediately a thorough carb cleaning is in order.
that tank is ripe for an electrolytic cleanout with washing soda and a strong battery charger.  Fill the tank with sodium carbonate (Arm and Hammer washing soda-not baking soda 1/2 cup to a tank of water and place the negaitve cathode in the tank and the positive anode connected to bare metal.  The rust will migrate from the inner tank to the cathode releasing rusty foam.  Overnight will do it.  I use a piece of rebar bent in an L shape for the cathode and insulate with plastic aerosol can lids and a peanut butter jar lid at the filler.  Works great and you won't need to paint sealer in the tank.  It will also spare the original paint.

I have used that method before but this time just a good soak with Evapo-Rust did the job.

I had it running before teardown. Reply #25.

Compression excellent. Reply #15





Thanks for the reply.

tt

[toytuff]

Well it's nice to be going the other way! 

Tire showed up yesterday so first thing this morning was down to the local dealer for tire mounting. I feel in love with a Vulcan they had on the showroom. Pics later in "other bike" thread.

 



 



Don't stop!



Mock up.



Ready to mount when the front end gets finished.



Time to take the rest of the weekend off. Well, maybe.

tt

[Stev-o]

Very nice, you deserve a margarita amigo!

[toytuff]

Very nice, you deserve a margarita amigo!

That's a great idea!

tt

[toytuff]

Should have all the paint work back tomorrow with the exception of the lower forks. Having those painted but weighing out options.

Went to install new points but the wrong ones. Honda lists several. Working on that also. 



Did a little mock up this morning. Wanted to see where I was going.

Headlight area.





Speedometer and top clamp area.



And a glamor shot. 



Rear fender next as well as the chain. Soaking the chain now but need to find some kerosene or other substitute for a good cleaning.

tt

[Stev-o]

The money shot!  Is there a steering dampener on the upper triple?