Author Topic: CL160 - Build Thread - CB160 (Read 7654 times)

OakBehringer · « **on:** October 11, 2009, 04:42:29 PM »

CL160 build!

I did a 350F top-end rebuild last winter, as well as cosmetic work on it. That bike is now beautiful (see signature links), so it's time to move on to a totally different build.

This will be my first go at an aesthetically creative venture. I see in my head what the completed project will look like, but I won't ruin the ending- subscribe to my thread and you'll find out.

Every part of this bike is going to have to be touched, so buckle-up and enjoy the ride.

then

then

- Cleaned and rebuilt carbs.
- Took the gas tank down to bare steel, sanded it all in the same direction, only going to clear coat it and put the emblems and knee bads back on. The color of this bike will come from the frame.

- Started to tear into the motor...

..and found this:

Top two rings are seized, bottom is cracked. No sign of the extra pieces, so it looks like I'll be doing a bottom end rebuild, too.

Crack open the left cover... WHOOPS! Forgot to drain the oil...

I work in my apartment, so oil spills are BAD.

Right cover open... about to pull my first transmission off...

WHAT A PAIN - NEED TO ORDER A LOCK WASHER SOCKET (highlighted red)...

So I moved onto the rear wheel. It took hours to scrub these brake parts.

Side collar is scored pretty bad, will have to be replaced....

And the bottom bolt broke when I was turning the nut, so I decided to call it a night.

OakBehringer · « **Reply #1 on:** October 11, 2009, 04:48:44 PM »

Can I crack the cases as-is? I could then bring the oil filter rotor to a shop that would have a locknut socket... faster and cheaper than ordering and waiting for one to come in the mail.

strynboen · « **Reply #2 on:** October 12, 2009, 08:58:32 AM »

hey i have made one of a old spark plug top set,,just saw in it until goes on,,i,m from denmark så speak not english,,

crazypj · « **Reply #3 on:** October 12, 2009, 12:36:56 PM »

That's normal wear on axle spacer, no point in replacing it, the grease seal will work just fine.
probably wasn't any need to remove sprocket studs, remove the big circlip and lift sprocket off hub with them still connected to it ( or were you replacing sprocket?)

PJ

OakBehringer · « **Reply #4 on:** October 12, 2009, 12:48:45 PM »

Quote from: crazypj on October 12, 2009, 12:36:56 PM

That's normal wear on axle spacer, no point in replacing it, the grease seal will work just fine.
probably wasn't any need to remove sprocket studs, remove the big circlip and lift sprocket off hub with them still connected to it ( or were you replacing sprocket?)

PJ

Thanks for the tip on the spacer. I'll cross that off my shopping list.

Didn't realize that removing the circlip would allow me to remove the sprocket without unbolting the studs, until a few minutes ago when I removed the circlip. Oh well, the busted one looks like crap. I'll be happy to have it replaced.

OakBehringer · « **Reply #5 on:** October 13, 2009, 04:42:56 PM »

Anyone have any tips on removing the rear wheel bearings without buying a bearing removal tool?

Thanks,
Adam

crazypj · « **Reply #6 on:** October 14, 2009, 05:11:49 PM »

propane, heat up hub. (it gets real hot when braking so heating wont be a problem as long as you heat 'even' all round)
It will expand and bearings can be knocked out easy

tomkimberly · « **Reply #7 on:** October 21, 2009, 05:46:43 PM »

Quote from: OakBehringer on October 13, 2009, 04:42:56 PM

Anyone have any tips on removing the rear wheel bearings without buying a bearing removal tool?

Thanks,
Adam

$ 39.00 at Harbor Freight. I just bought one today for my S90 project. The bearings are easier to remove if you keep the hub and spokes assembled.

Tom

helgiman · « **Reply #8 on:** October 22, 2009, 05:18:52 AM »

Go for it! The old 160's are a lot of fun. Here are a few pics of my recently completed project.
Ed

HondanutRider · « **Reply #9 on:** October 22, 2009, 06:06:09 AM »

"WHAT A PAIN - NEED TO ORDER A LOCK WASHER SOCKET (highlighted red)..."

Rather than getting a specialized tool, you should be able to knock the threaded washer off with a small bar of soft steel or brass. (Its actually a nut with a slotted head, I believe.) Resist the temptation to use a hard steel end of a screwdriver or chisel, as they will gouge the slots of this washer worse than a bar of soft steel or brass.

OakBehringer · « **Reply #10 on:** October 22, 2009, 10:42:42 PM »

Quote from: HondanutRider on October 22, 2009, 06:06:09 AM

"WHAT A PAIN - NEED TO ORDER A LOCK WASHER SOCKET (highlighted red)..."

Rather than getting a specialized tool, you should be able to knock the threaded washer off with a small bar of soft steel or brass. (Its actually a nut with a slotted head, I believe.) Resist the temptation to use a hard steel end of a screwdriver or chisel, as they will gouge the slots of this washer worse than a bar of soft steel or brass.

Because of the location, inside the oil filter housing, that wasn't possible. I ordered one for about $10 and got it today. No problemo.

OakBehringer · « **Reply #11 on:** October 22, 2009, 10:52:58 PM »

UPDATE!

Unspoked the back rim and frowned at the rust:

I was considering having them powder coated, but they cleaned up better than I ainticipated, so I'll see how they fair for a season:

Got the oil-filter housing off via my new lock-nut removal tool, split the cases:

That was pretty exciting, as I've never gotten into a bottom-end before.

Refer to the beginning of the thread, where I mention the busted up piston, for the next couple pics.

Anyone need any finely ground alloy? Looks like this bike was run for a while with piston chunks in it:

Oh, and maybe this has something to do with the piston breaking? One of connecting rods... well... it moves around a hell of a lot:

Got a weekend of travel, unfortunately, so I won't be able to get any more done on this for a few days. Thanks for reading!

GoatBaSS · « **Reply #12 on:** October 22, 2009, 11:45:08 PM »

Go forth squire I await great things with your return.

douft750 · « **Reply #13 on:** December 05, 2009, 03:49:45 AM »

Great looking build. Thanks for posting all the photos.

Here is a link to my 1969 CB160 build:
http://www.classichondabb.com/forums/showthread.php?t=29

I'm at about the same spot as you are right now.

Sam Green Racing · « **Reply #14 on:** December 06, 2009, 04:36:20 PM »

Looks like you may be looking for another crank.
The main bearing has completely disintegrated and could have damaged crank or rod or both.
I would just look for another crank.
It's hard to believe that a motor can be run to that degree, it must have been knocking it nuts of for about 20 miles to get in that state, I know this as I had a mate who did it several times.

Sam.

OakBehringer · « **Reply #15 on:** December 08, 2009, 11:39:16 AM »

Quote from: SamCB750A on December 06, 2009, 04:36:20 PM

Looks like you may be looking for another crank.
The main bearing has completely disintegrated and could have damaged crank or rod or both.
I would just look for another crank.
It's hard to believe that a motor can be run to that degree, it must have been knocking it nuts of for about 20 miles to get in that state, I know this as I had a mate who did it several times.

Sam.

At this point, I've got a line on a running 175 sloper that I'm hoping to swap in. If that happens, I'm going to gut this one, paint it nice, and use it for decor atop my kitchen cabinets:

I've really slowed down on this build b/c I found a CT70 on craigslist for $175. Spent a couple weeks getting that from crashed barn find to reliably running, but I'm back on the 160 now. My seat should be shipped from Airtech today- so I'm hoping to have a roller by the new year.

-Adam

OakBehringer · « **Reply #16 on:** January 18, 2010, 11:51:47 PM »

Got a bit more work done since my last update... ground the sh*t out of my frame, finished both rims, got the forks apart, stripped a ton of paint, aquired a CB160 tank, got my Airtech seat, etc, etc, etc. Not really anything picture worthy, yet, except the hubs I finished polishing tonight. Not my best polishing work, but I'm happy with them. A man can only take so much wetsanding before he loses his mind.

Sam Green Racing · « **Reply #17 on:** January 20, 2010, 12:52:31 AM »

Did you get the sloper motor Adam? hubs look real good

Sam.

OakBehringer · « **Reply #18 on:** January 20, 2010, 07:32:13 AM »

Quote from: SamCB750A on January 20, 2010, 12:52:31 AM

Did you get the sloper motor Adam? hubs look real good

Not yet Sam, just trying to get everything except the motor finished before I get on that. If you know anyone with a 160 sloper for sale, let me know!

bryanj · « **Reply #19 on:** January 20, 2010, 08:30:02 AM »

We have had other pictures of pistons like that, its where the piston skirt jams in the crankcase oppening when crank turned--seen lots like it that still run ok

As to the shot big end, easiest is a good used replacement but here in UK we have Alpha Bearings who will repair/replace rods, pins, and bearings so surely there will be a firm in US that does the same

crazypj · « **Reply #20 on:** January 20, 2010, 02:01:15 PM »

Don't think there is anything like Alpha Bearings here, except at industrial prices.
you can get just about anything done, but, its real spendy
Doubt if anyone knows how to work on overhung crankpins though?

PJ

OakBehringer · « **Reply #21 on:** January 20, 2010, 02:02:54 PM »

I'll probably be able to get a second motor for close to or less than the price of any of that. That's the plan for now.

News:

Author Topic: CL160 - Build Thread - CB160 (Read 7654 times)

helgiman

douft750