Loooong project CD175

[grahamd1]

I took my test (too many years ago) on my trusty cd175, so I have hankered to find another, but the cost of them is silly on fleabay, then I came across this wreck for not a lot, and well, just had to have it (even the wife nagged me to get it, as she remembers my old one well). and voila one 1972 CD175 that has spent the last 20+ years in the back os someones shed. I drove 140miles this morning to collect it, and its amazing what you can squeeze into the back of a Picasso

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/ebayp2.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0276.jpg
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

Wahay, got the engine out, however do have a problem with the carb, more on that later.

https://i314.photobucket.com/albums/ll431/grahamdrry/IMAG0285-1.jpg

Took the top off the carb so I could pull out the throttle slide so that I could take the engine out complete with carb BUT, the damn slide is stuck solid (crud fuel!!!) and wont budge, with the throttle cable stuck in situ. So I took the carb off to enable me to get the engine out, but I'm buggered if I can get the cable or slide out of the carb, I've soaked it in penetrating oil and paraffin, but so far no go, and I dont want to damage it, suggestions ?
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[hadden]

hi mate.looks like this could be a good project.im no expert by all means but if it was me i would either get dw-40 down there and spend a good hour wiggling it.or search the net just incase there is a knack to it.you never know.
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red bull gives you wing sting!!!
current:aprilia rs 125
previous:honda c90,honda cm 125,yamaha xt 550,2004 suzuki drz 400.(all used for off road back in the day)and a piagio zip 50cc..oooossssshhhh

[virus]

your going to have to completely strip and clean the carb anyway so drop it in a vat of diesel overnight, that will unsieze it.

Cheers
John
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own: 81 xs1100g...
owned: 85 rat CG (sold), 91 GS500e (stolen), 84 gsx400f (scrapped), 81 z250 (siezed, siezed, scrapped), 83 cb250rs (sold), 84 gpz750r ratfighter (killed) 84gpz400 (sold), '80 cb650 ratfighter (wrote off) 95gsx6/12f ratfighter (killed) 91 xj900 (sold)
stinkwheel Well I just had my hands up a pigs fanny. Which makes your concerns pale into insignificance.

[pepperami]

This ^ +1
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I am the sum total of my own existence, what went before makes me who I am now!

[grahamd1]

In the end I took some cutters to the throttle cable (having checked I could still get a replacement), and that allowed me to bring the carb into the house for examination. Took the top off and wiggled the inner throttle cable till it came clear of the slide, then again sprayed and soaked the carb in brake cleaner/wd40/penetrating oil. Went back a few hour later, and nope still not moving, so I tool the rear fly screen (a small mesh over the air intake), and could just see the bottom of the slide, so using a small bit of wood wedge shaped, I kept pushing and working it in, till it moved a little bit, then more spray, more wedging, untill it came out. What was holding it was cruddy sediments of old fuel, almost like tar. Tonight I'm going to strip it right down, and give it a soak in the ultrasonic bath.

I've also removed the handlebars (not sure if they are saveable), and the front headlamp cowl with the speedo. Just tried a drill in the speedo and that works fine, BUT its discoloured over the years of neglect so I'd like to strip the speedo down and give that a clean. But its made of metal and although I can get the screws out of the back (talk about rusty), its clear that disasembly requires the guts to come through the glass front aperture, and from what I can see the glass is held in by the front chrome (ISH) bezel, formed over a lip around the speedo. So removing the glass so I can get at the guts is gonna be a bugger.

Whilst playing yesterday, I discovered it had a cheapo tin horn fitted, rather than the original oem part (I loved the sound of the original), but luckilly I found someone selling an original, so its on order. Also no iginition switch (hard wired), so again found someone with an original one with braket and original Honda keys. the helmet lock and steering lock keys are also missing, but they look servicable. I did a search on the net and if I send my helmet lock to a specialist they will cut a key to match (steering and helmet lock are the same key), for about £12.
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

All in all the condition is not as bad as it looks, at some point someone has cared for her, as touch wood nothing has broken when being dismantled (inc bolts/screws).

The bottom head steady bracket is before 10 minutes with the dremel, and the top one is after, but I'm going to sand them down to the steel again before priming.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0280.jpg

Even the rear wheel looks like it will sucum to the charms of dear old mr dremel (first pic is before)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0281.jpg https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0283.jpg

Might change the spokes though, and the rims will never recover, too badly pitted, I see DS has them listed as spare parts and available so I could keep the hubs ad just change the spokes and rims.

Tried the dremel on that flaky corrosion on the engine and again it looks like it will come off ok

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0286.jpg https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0287.jpg
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[CHR15]

if your rebuilding the engine, might as well get it soda blasted. it ill bring it back to factory finish.
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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.

[grahamd1]

[grahamd1]

Currently stripping down the carb, YUK the bottom was 1/2" of dried crud, tried brake cleaner and crappy carb cleaner from Halfrauds and nothing seemed to touch it, so I brushed it out with the dremel (copper wire brush). Again brake cleaner and carb cleaner wouldn't touch the stains left, so I called in on my local car garage, and got a tin of this, its the bees knees, first blast does nothing, second blast and the stain starts running, a quick wipe with a cloth, and another blast and it looks clean. I'm going to soda blast (from an article on here) the outside once I've repaired my compressor.

This was the stuff I got (£2 a tin,,, bargin)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0293.jpg
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

Tonight I managed to remove the swinging arm, and I'm a happy bunny its in great shape, and so is the bottom of the frame, even the bolt came out easy, and the barings look ok, no slop, just as well.

Took the front forks off the frame, rubbed them down with wire wool and oil, and they also have come up nice, but I want to strip them down to replace the fork seals, BUT I cant remove the chrome lower fork covers (manual says they are screwed on), the haynes manual talks of a "Special" honda tool "Peg Spanner" being required, fat chance after all these years. They suggest an alternative is a strap of chain? Tried using a leather belt, nothings moving, reluctant to use a chain in case I further destroy the remaining chrome.

Anyone ?
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

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

Got the swinging arm out of the frame last night, and I think where the enclosed chainguard has been removed sometime in the past, that has saved the old gal, by spraying chain oil over the frame and swinging arm.
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[LongJohn22]

This thread really needs more pictures.

[grahamd1]

[deleted111]

Watching with interest, my Grandpa had one of these!

[grahamd1]

Thought I'd strip off the controls from the handle bars and check if they were salvable. Once removed I gave them a good squirting with the carb cleaner shown in above posts, as it just blasts away greece and other grime. Then I cut off the old heatshrink tube (will replace that with new later), and set about cleaning/testing.

This is the RH unit (turn) before using a dremel with Solvol

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0310.jpg

and a few hours later

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0311.jpg

Heres the otherside

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0308.jpg

And the set together

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0312.jpg

I've also checked the switch/wires for continuity (sprayed some switch/contact cleaner in for lubrication) using the circuit diagram and my fluke dvm.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0319.jpg

Amazing 20 years of sitting in the damp and a little bit of love and they work and look fine.
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

Also attacked the front and rear hubs and brake arms (using same treatment)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0315.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0317.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0314.jpg
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[herulach]

Those control pods are pimp, want.
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YBR 125>FZS600

[LongJohn22]

I love this stuff, keep it coming!

[grahamd1]

Wahay, frame now naked, ran a wirebrush (on my battery drill) over the frame to check for any holes or problems, and shes good to go. So first coat of paint stripper has been applied, and rubbed off, second coat will be applied tomorrow.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0320.jpg
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

Also did some more rubbing down of some of the grubby parts.

In this case the rear wheel adjusters

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0322.jpg

And after

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0325.jpg
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

Now lets see whats lurking under the head stock ?

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0323.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0326.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0324.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0328.jpg

Camera doesn't do the parts justice, in fact they are so shiney you can see your face in them.
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

Frame is almost stripped of paint, I'm amazed at the condition for a 40 year old Jap bike

So far 2ltrs of nitromors, and two copper wire brush attachments for the drill, worn down to the hub.

I also took the rear tyre off the rear wheel, NIGHTMARE, the rubber seems to have gone rock hard, took me over an hour with 3 tyre leavers (by the way Poundland has motorbike tyre leavers at the moment £1 each), damn tyre fought me every inch. I think the rim is a no,no I see Davis Silver has new rims, but doesnt mention spokes, also some time back someone mentioned somewhere that did wheels and offers a rebuild service ? Anyone ?
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[Damon]

I'm liking this build very much. Keep up the good work

Gonna be great hearing it start up again after all these years! Are you going to replace the bearings in the engine? or just oil it and see?

Thanks,
Damon

[grahamd1]