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grahamd1 |
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grahamd1 Trackday Trickster
Joined: 04 Aug 2011 Karma :
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Posted: 15:47 - 28 Jan 2012 Post subject: |
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I took my stearing bearings out the other day, ok I should have done this before I sent the frame away for coating (senior moment), but no problem, and no damage done.
The other day I tool the old ones out of the headstock (should have done this before I sent the frame for powder coating, but then we all live and learn).
Used one of my largest steel punches and gently tapped all the way around a quarter of a turn (ie 12oclock, 3 oclock, 6 oclock) at a time
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0286-1.jpg
And out it popped (bottom retainer cup)
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0287-1.jpg
With the bottom one out, you can see the top one (frame upside down), and the lip you need to push against
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0289.jpg
Till that one also comes out.
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0291.jpg
Just as a reminder this was the stearing head when I removed the bearing cup holder some time back
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0351.jpg ____________________ XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild), |
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grahamd1 |
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grahamd1 Trackday Trickster
Joined: 04 Aug 2011 Karma :
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Posted: 23:13 - 29 Jan 2012 Post subject: |
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When I first started this project I tried to remove the lower fork chrome covers, but with no luck at all (see below)
grahamd1 wrote: | This morning I took the forks to a local engineering company, and we tried all manor of clamps (oil filter, canvas webbing, chains), and NOTHING budged, out of deperation we cut some steel tube and drilled two holes with two 10mm bolts screwed in that fitted into the pre-cut slots (used by honda with their peg spanner), and ?
NOTHING, even 3 of us pushing and twisting (they fit like a bayonet, 1/4" turn then pull off), no way were they shifting. Took a micro camera and inserted it into the stanchions to have a look at the fork seals, and they are in great shape, so worse case I aint gonna change them. |
Now I could just turn a blind eye to the fact that I cant get them off without destroying them, and hence not change the fork seals, BUT no way, this has been bugging me for a while now. Then right on cue a pair turn up on fleabay, brand new (NOS), and I got um.
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/forks.jpg
This diagram (part 5) shows the items, now I dont care if they bugger up when I try to get them off, I have two shiney new replacements, may seem a bit harsh, but its the only way I can be sure, and CAN now change the seals.
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/forks2.jpg ____________________ XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild), |
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grahamd1 |
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grahamd1 Trackday Trickster
Joined: 04 Aug 2011 Karma :
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Posted: 21:10 - 02 Feb 2012 Post subject: |
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And so time to start putting her back together
First item was the battery box, the heart of the bike.
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0310-1.jpg
Next was the ignition switch (got this off Fleabay as mine was hard wired, yuk)
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0309.jpg
Next was the horn (also replaced non original part), and the twin coil pack. (Notice the new 3.9mm jap connectors I have already changed on the loom)
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0307.jpg
And the Selenium rectifier (now adays this would only be a half wave recitfier and about 1/10 the size), this think was fillthy, so I stripped it down and cleaned it up, testing not only the diodes were ok, and ensuring they went back the correct way, but also testing the wires and plugs.
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0306.jpg ____________________ XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild), |
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grahamd1 |
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grahamd1 Trackday Trickster
Joined: 04 Aug 2011 Karma :
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Posted: 20:04 - 05 Feb 2012 Post subject: |
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Moving SLOWLY onwards, I installed the baffles in the bottom case (these limit the amount of oil that gets thrown off the big ends).
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0319-1.jpg
And loosley tried the gears, crank and kickstart assemblies in the bottom of the case, so far so good
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0320-1.jpg
Also removed the old oil seal from the gear selector output
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0322-1.jpg
Old seal on the rhs
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0321.jpg
Next the gear selector (the CB has 3 selectors, the CD only 2)
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0317-1.jpg
Then went to get the top case from the plastic box they were sent for vapour blasting in, when I noticed the case move on its own!!, further investigation revealed;
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0318.jpg
Yep, a tiny field mouse had moved in, probably the -9c and snow outside, and thought it was cozy in my damn workshop! I'm afraid he (she?) is out on their ear, and BACK in the garden, it looked a bit misserable as it ran off across the snow, SHAME...
Meanwhile, having loosley installed the gear selectors, these slots are engaged with the 14mm bolt (and lock washer) that then guides the selectors, that change the gears (push & pull)
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0323-1.jpg
And the assembly is now checked, and all looks ok
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0324-1.jpg
A quick question to anyone reading ? I notice the top and bottom cases have traces of liquid gasket where the bearings (top and bottom) sit in the cases, I'm surpriced, not sure if I should do this or not? ____________________ XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild), |
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CHR15 |
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CHR15 Turbo nutter bastard
Joined: 14 Jun 2008 Karma :
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Posted: 20:56 - 05 Feb 2012 Post subject: |
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thats interesting, are the crank scrapers standard fitment?
also, do the conrods sit on the piss or is it just a trick of the picture? ____________________ Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible. |
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Tim.. |
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Tim.. World Chat Champion
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grahamd1 |
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grahamd1 Trackday Trickster
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Teflon-Mike |
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Teflon-Mike tl;dr
Joined: 01 Jun 2010 Karma :
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CHR15 |
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CHR15 Turbo nutter bastard
Joined: 14 Jun 2008 Karma :
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Posted: 16:20 - 07 Feb 2012 Post subject: |
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Blue is correct for his situation. The crankcase halves have no gasket. ____________________ Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible. |
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grahamd1 |
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grahamd1 Trackday Trickster
Joined: 04 Aug 2011 Karma :
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Posted: 21:48 - 08 Feb 2012 Post subject: |
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Yep no gasket, I called a local Honda dealer who confirmed they use Blue when joining gear cases on old twins.
Another damn fiddly job (and little ref in any of the pics in manuals) was putting the gear selector cogs/gears back in place with the springs corretly working
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0331-1.jpg
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0332-1.jpg
I feel very satisfied, when I move the wheel manually through the gears and neutral and see the gears slide on the selectors, poetry in motion...
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0333.jpg
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0334.jpg
Also got around to installing my stearing head bearings (Pyramid tapered rollers)
Here I'm packign the lower bearing in grease
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0335.jpg
And the top one is in place
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0336.jpg
Also picked up a second engine (stripped plug hole), great for spares, and quick ref (wish I'd had it when I was doing the gear selectors/wheels).
Thats it for a week, off to Teneriefe at the crack of dawn, no more damn snow or ice, only cold beers and warm pools. ____________________ XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild), |
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grahamd1 |
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grahamd1 Trackday Trickster
Joined: 04 Aug 2011 Karma :
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Posted: 20:28 - 17 Feb 2012 Post subject: |
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Back from my week in the sun (Fantastic)
Thought it was time to do the job I had made feable excusses not to do?
The front fork seals!!!!
As I was lucky enough to get a NOS pair of chrome fork shrouds, I wasn't too worried if I destroyed the old ones in the process (one did, one came off easy), in the end one was a nightmare, and one came off with some persuation from a rubber mallet and some hard plastic (durol) nylon rod. for anyones interest these sleeves ONLY slide on and are then turned (BY HAND ONLY) to the correct position, using the two indents on the sleeve in the short grove in the fork, then twisted about 1/4". NOTE by hand, ie to remove them they should just pull up, no real need to twist them, just get them moving up and down 1/4" (adding lots of penetrating fluid) then they should just twist off. (see arrow)
Once off I removed the circlip holding the oil seal in place.
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0386-1.jpg
then I bashed the lower fork on a wooden floor till the spring inside pushed the oil seal out.
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0388.jpg
Then a problem !!!!
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0390-2.jpg
the seal on the left is the new replacement (Pattern) part, the one on the right is the original, about 1/32" too long, result is the circlip that retains the seal will not sit in the groove in the fork shroud!!!!!!. I ground mine down, and no problem, now the circlip fits fine.
Applied lots of greece over the oil seal, and around the top of the fork shroud (just in case I need to take those chrome sleeves off again)
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0389.jpg ____________________ XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild), |
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grahamd1 |
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grahamd1 Trackday Trickster
Joined: 04 Aug 2011 Karma :
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Posted: 11:10 - 19 Feb 2012 Post subject: |
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Still can't believe I had to grind the fork seals down, I checked the Honda parts manual and its states 31mm,41mm,11mm. The ones I got (wish I could remember which fleabay seller it was, but as its over 60 days its not in my history), as these are 31mm,41mm,16mm.
Might re-open them and order some "genuine" replacements, but this time will measure them..... ____________________ XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild), |
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grahamd1 |
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grahamd1 Trackday Trickster
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Oldgrumpy |
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Oldgrumpy Derestricted Danger
Joined: 07 Jun 2010 Karma :
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Valentino Mossy |
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Valentino Mossy World Chat Champion
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grahamd1 |
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grahamd1 Trackday Trickster
Joined: 04 Aug 2011 Karma :
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Posted: 21:26 - 03 Mar 2012 Post subject: |
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Thanks guys, and yes the CD175 is 6volt (and yes I could convert it, but I aint, I doubt I will ever ride it in the dark, so leave as is).
At last got my replacement fork seals, funny enough the same box (same make), and same part number BUT smaller ????
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0394-1.jpg
To recap, the problem is the seal sits on this lip in the stanchion, and the retaining circlip locates in the upper ring, and with the larger seal it was impossible to install the circlip
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0395-1.jpg
Now the upper forks and springs/dampers are inserted back into the stanchions
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0396-1.jpg
This is the circlip (awaiting compression before sliding down the bore into the retaining grove
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0440.jpg
Now the circlips fits with ease
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0441.jpg
Next I covered the top of the stanchion and clip/seal in ACF-50 (Anti-corrosion grease) to ensure water STAYS OUT
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0444.jpg https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0442.jpg
These are the locating pips inside the chrome fork covers (again inside coated in ACF-50)
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0443.jpg
Job done (and should come apart if required)
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0445.jpg ____________________ XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild), |
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Valentino Mossy |
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Valentino Mossy World Chat Champion
Joined: 13 Jul 2003 Karma :
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Posted: 23:33 - 03 Mar 2012 Post subject: |
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That grease, would that be good to use on my swing arm shaft which goes through the frame,engine,bearings,swing arm and bushes ?
Might try it on the single sided rear hub as most of the grease i used last time has manked up a bit... ____________________ Ducati 916,white framed corse replica https://www.bikechatforums.com/viewtopic.php?t=239309
Ducati 160 monza jnr soon to be cafe racer
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Hobgoblin |
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Hobgoblin Trackday Trickster
Joined: 05 Feb 2012 Karma :
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Posted: 22:21 - 09 Apr 2012 Post subject: |
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grahamd1 |
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grahamd1 Trackday Trickster
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pepperami |
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pepperami Super Spammer
Joined: 17 Jan 2010 Karma :
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Posted: 19:34 - 20 Apr 2012 Post subject: |
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Loving it more please! ____________________ I am the sum total of my own existence, what went before makes me who I am now! |
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grahamd1 |
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grahamd1 Trackday Trickster
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Posted: 17:43 - 01 May 2012 Post subject: |
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Got an engine off Fleabay the other week (CD175) went for £10 as one of the sparkplug threads was stripped, and a week later I got a head off fleabay (inc valves and cam shaft) for £12, so got a spare engine for £22, BARGIN. Just to add to the pile this weekend I got a bottom end (minus head and barrel) for £5, the reason is I can use this bottom end as my reference in getting mine back together ____________________ XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild), |
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N cee thirty |
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N cee thirty Banned
Joined: 31 Jan 2010 Karma :
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lizard821000 |
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lizard821000 Nova Slayer
Joined: 19 Mar 2009 Karma :
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Posted: 15:16 - 24 Jun 2012 Post subject: |
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great read this mate!
ricky over on greybike pointed me in your direction, doing up an old 76 cb200.
about to split the engine, complete rebuild. bottom ends fked.
might hit you with a few questions if thats cool, just about parts suppliers and stuff lad.
shaun ____________________ yeah baby!! |
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GrumpyGuts |
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GrumpyGuts World Chat Champion
Joined: 20 Jan 2012 Karma :
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Posted: 00:44 - 25 Jun 2012 Post subject: |
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Great bump, never would have seen it otherwise.
You deserve all the praise you get for this, well done. Well impressed ____________________ My Bikes: Lifan Beat 125cc '11 -> Suzuki B120P '76 -> Suzuki EN 125-2A '08 -> Honda CG 125 '04 -> Honda CB600F Hornet '98 -> Kawasaki ZZR 600 '99 -> Kawasaki GPZ 500S '95 (Current)
Theory test passed - 09/02/2012 >>>> Module 1 passed 24/07/2012 >>>> Module 2 passed 24/10/2012 |
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grahamd1 |
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grahamd1 Trackday Trickster
Joined: 04 Aug 2011 Karma :
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Posted: 20:42 - 25 Jul 2012 Post subject: |
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Well after a long break of many months I now have a few of my other projects put to bed (inlcuding a troublesum problem with my XV750, thats taken months to diagnose, let alone repair), but in the end I'm back at it.
Although I havent been posting, I have been gathering parts here and there for the old gal (more on that later), so tonight (despite the heat), I finally did what I've been putting off for ages, and got the cases back together.
First of I did a dry run to check it all fits correctly.
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0967.jpg
All looks like it fits where it touches, which cant be bad. Next I liberally ran assembly lube over every moving part.
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0969.jpg
Time for the real coming together, and copious amounts of Hylomar Blue , before putting all those differnt length bolts back in place.
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0970.jpg
Gently pulled up all the bolts in diagonal order (both 10 and 12mm bolts), till the cases were sealed, then wiped off the spare Hylomar where it had squeezed out.
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0971.jpg
Now to leave her to set overnight.
My orignal fork shrouds and headlamp holders were rusted and cracked to buggery, so I've managed to get some odd replacements (the blue ones are NOS I managed to get as the very last stock from David Silver, shame he didnt have left and right, but hey ones better than none).
https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0972.jpg
Whilst painting my other projects over the last few months I've become very dissatisfied at the off the shelf rattle cans (Halfrauds Acrylic based), they just don't seem up to the job, no matter how many coats of primer/top coat/clear laquear I've used they still scratch if you so much as fart near them, crazy thing is I have several air spray guns (HVLP) I have purchased over the years to use with other hobbies, and have never used them! So rather than go down the 2k (two part) paint route with all the crazy safety problems involved with air fed masks etc, I'm going to go down the epoxy route (more to follow). So thats the next step on the frame/build to have a play with the fork shrouds and see how I get on. ____________________ XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild), |
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Old Thread Alert!
The last post was made 11 years, 300 days ago. Instead of replying here, would creating a new thread be more useful? |
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