Topic: 1969 CL 450 Restore for a friend.

[Markcb750]

Mark,  that mutilated clutch actuator is normal as many owners would spread the holder inorder to get a new cable in, then after buggering it they would squeeze it back together so the cable would not pop out.  Nice repair...Larry

Yes it does seem to be  common, 2 of the three replacement parts I acquired had the same problem.

Got the swing arm, shocks and chain guard on today, the bushings are in great shape. off to the hardware store before it closes.

[Markcb750]

Lots of progress, no photos.

Replacing the connector from the alternator & neutral safety switch, earned a valuable lesson about examining the wires closely before cutting.  the wires from the motor side are not the correct color or faded beyond recognition. I can sort out all but two, the two that connect to the battery charging circuit. I suspect it won't matter because they carry AC...

Both wires have the same resistance to the third identifiable wire. So I guess I will not assemble that half of the plug till I can run it in a few weeks...

I need a front fender reflector, if anyone has one Please let me know.  (pic below)

I disassembled an eBay sourced speedo, patience and a little blood and they come apart better then I thought when I did my 750, and it sure makes painting the shell easy, I also am going to acquire a new faceplate. Looks like one of the eBay specialist (catiawheels) has one.

I mentally added up how much I have spent on hardware, ss & plated. Approaching $200 with another eight bucks today.

[Markcb750]

Just a few current pics.  Have learned a lot about gauges...nothing positive just things never to do again.  I am making an attempt to scan in the faces but I think a good cad drawing would be best for a reproduction.

Later

Mark

[The Mayor]

Those gauges are from a later model 450, no? I've picked up a '69 CL450K1 and have different ones on mine...

[Markcb750]

yes they are from a 72, it had gauges from a 350 when I took it apart.

[The Mayor]

If anyone knows how to take apart the k1 gauges here, pm me! Great work on the restore, I can't wait to get mine looking (hopefully) something like that - beautiful bikes.

[Markcb750]

I have salvaged the guts from the original '69 gauges, the cases where cracked and some of the odometer dial numbers where gone.  Could not find replacements but have determined I can put them into newer (metal) cases if I ever take on the challenge of restoring the black face gauges.

FWIW  a big old Bronx's  salute to the engineer on the 72 gauges who used oversized nuts on the 8mm bolts that hold the bezels on.   

[The Mayor]

Yeah my gauges and face plates are actually very clean, but the speedo stopped working and the tach is a little noisy as well; I was hoping to open them up find a fix, but if I remember correctly it was as if the plastic housing was almost molded around the base plates of the guts? (don't have them in front of me to look at)

[Nikkisixx]

FWIW  a big old Bronx's  salute to the engineer on the 72 gauges who used oversized nuts on the 8mm bolts that hold the bezels on.   

Those not only hold the bezel on but also act as an upper fork brace 

Looking good man!

[the-chauffeur]

Sorry to dive in, but I had the same problem with the clutch actuator arm on my 450 K6 after swapping the front sprocket - in fact, I found the end had basically been smashed off despite what I thought was very careful alignment.

It took me a while to figure out what had happened, but it turned out that it was the pins on the chain split link.  They were fractionally too long and clipped the cable mount when the chain moved across the sprocket.  Reconnecting the link with the outer clip on the chain side facing the wheel was the solution.

Good luck with the build . . .

[Markcb750]

the-chauffeur

Clutch update.  I finally got the chain and clutch lever and cable assembled.  could not get it to adjust properly yesterday.  This morning i woke up with an idea that if i increased the size of the ball bearing in the actuator i could move the angle of the lever arm, so off to the hardware store (again) where I bought an assortment and wella changing from the 0.280 ball to a 0.3125 ball Put it right where it should be.

Also had to fabricate a new RBBB  (or stop)  for the center stand but it is coming together well.  obsessing over details like the proper length of bolts causes far to many trips to the store.  today I was halted by the rear foot peg bolts.  But lots done. 

[Greggo]

Lookin' Good!

[Markcb750]

Got the exhaust cleaned & mounted.  I polished the motor area with both No7 chrome polish & black rouge on a cotton buffing wheel.  Even the dark rusty areas polished up, not new chrome good, but nice.

I cleaned the exhaust ports and wire brushed the old copper exhaust seals,  wont know if it re-sealed properly till I get it running.

there is something loose (a baffle i am sure) inside the muffler, but it is in good shape.  I sprayed the hell out of the inside with wd40 as I do my 750 when I know it is going to sit  after a ride. theory being it will drive off any water and leave behind a little oil.  The bottom drain on the muffler is rusted pretty badly, I will paint the area with HT paint  but that is where the exhaust will fail first.

None of my photos of chrome come out well, it all looks much better then the photos show.  I need to wait for sun to try again, the exhaust flange area looks great but every photo looks dull/out of focus, must be tooooo shiny.

As part of cleaning up the wiring I want to move the flasher from the ignition switch area to inside the headlight bucket.  The rubber sock it mounts in has failed and is made from unobtainium.  Does anyone know that this would be a bad idea?

Later
Mark

[malcolmgb]

Before re-using the exhaust copper sealing rings you should have annealed them, it 'softens' the copper, done this before and it works provided they are not squashed flat.

[Markcb750]

Before re-using the exhaust copper sealing rings you should have annealed them, it 'softens' the copper, done this before and it works provided they are not squashed flat.

How would you do that without damaging them taking them out?

[malcolmgb]

I use a hook behind the ring, run it around to release it from the head, usually pops out easily if fitted dry.

[Markcb750]

I use a hook behind the ring, run it around to release it from the head, usually pops out easily if fitted dry.

I tried that on my 750 when I restored it, the seals where crushed to the extent I had to drive a sharp hooked awl into the edge of the seal to pry & extract it with out damaging the seat.  I did not even try with the CL 450.  Maybe next time.

Mark

[Markcb750]

Paint today, Thanks to Nikkisixx for the advice  and clear coat!

Not bad for a garage job.  IMHO

Try to start it tomorrow lets hope I do not have too interesting a day.

[Markcb750]

It's alive

to pat myself on the back, only wiring issue was in the RH handle bar control, an old repair (Not Mine) shorted the starter button, causing the starter to run as soon as I touched the battery +.

Started in just a few spins.  The carbs are much easier to set then the 750K6.  and the low-speed needle has an immediate effect!

Off to Americade in Lake George NY.  Anyone else going to be there on Thursday?

[MoMo]

Nice work, Mark.  That came out quite nice- I especially like the silver/black combo.  I am sure the owner will be thrilled...Larry

[Retro Rocket]

Nice work, Mark.  That came out quite nice- I especially like the silver/black combo.  I am sure the owner will be thrilled...Larry

+1...very nice

[Markcb750]

Thanks, I really enjoy doing this work.  Would be nice to be able to do just restores.

 I put the tank badges on backward!      Fixed

Aluminum forks.

Sand, down to 1000 grit., red rouge, white rouge, White diamond polish & sealer.

Still looking for the front fender reflector for less then hostage pricing. Let me know if you know of someone who wants less then five tanks of gas on my 750.

[Markcb750]

Here is my paycheck for doing the CL 450

What species of snake is that?




(I vote for Garter)

[lone*X]

Whoa.  Now that is a project!  What year?

[Markcb750]

Whoa.  Now that is a project!  What year?

It is a 1967K0  444 cc twin, four speed gear box.  I am going to pressure wash was the hell out of it first. then take it apart and start looking for parts.  First purchase; a shop manual.