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Loooong project CD175

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hadden
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Joined: 01 Nov 2011
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PostPosted: 20:15 - 26 Jul 2012    Post subject: Reply with quote

grahamd1 wrote:
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.



wish my tool chest was that shiney Sad can i have your postcode please so i can sneakily swap it?ill even leave the can of enamel for you Smile
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grahamd1
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PostPosted: 20:57 - 27 Jul 2012    Post subject: Reply with quote

Gear selector now back in (inc washer and spring clip), might take it back out and give it a damn good clean, looks a bit minging next to the other cleaned up parts.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0976.jpg

And the business side of the gear selector (tried and all 4 gears are selectable, and neutral is steady)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0977.jpg

Way cool moving the gear lever and seeing all those parts move in sync.
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grahamd1
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PostPosted: 15:57 - 29 Jul 2012    Post subject: Reply with quote

If you remember I found out my clutch basket was damaged, so today I swapped over the oil pump piston onto the replacement basket (added some assembly lube for good measure along the way)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0979.jpg

Basket installed and oil pump tested (well at least that the piston goes in and out ok) see arrow

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0980.jpg

FYI there are two types of clutch basket fitted to the CD175 (ditto cb and cb200), identified by there either being one or two gears. Getting a replacment with a single ring is ok, IF you can get a single output gear, like hens teath though, so yes I made that mistake, first replacment I got was, yes a single gear, and NO I could not find a single gear any where, ho hum. Luckilly I found the correct twin geared version shortly after I got the first (sods law), and thats the one going in.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0982.jpg

Not forgeting to bend over the securing tabs over the pump bolts, overwise a nasty accident could be waiting....

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0981.jpg

Drive pulley and oil filter tested in situ

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0983.jpg

And in with the clutch plates (best part is I have 15 to measure and use the best off, lol).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0984.jpg

finaly the clutch spring cover

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0985.jpg
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grahamd1
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PostPosted: 19:46 - 30 Jul 2012    Post subject: Reply with quote

Had a little time this afternoon, so I installed the Neutral switch (two parts, this is the contact part)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0986.jpg

This is the other part (goes on the end of the gear selector)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0987.jpg

Also installed the coils (generator) back into the side cover (getting ready to put the covers back on)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0989.jpg
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grahamd1
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PostPosted: 12:19 - 01 Aug 2012    Post subject: Reply with quote

Need some help if anyone can ?

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

I've discovered the bit the clutch cable goes into where it passes into the engine was missing, I've checked my spare engine and it also doesnt have one. The part number is 22875-216-000 and David Silver lists it as JOINT, WIRE !D , unfortunetly neither DS or CMSL have stock (I gather its the same part on CB125S, CL175, CB160, CB175, CD175 and CB200's). I found one on ebay.com but the guy is not accepting emails/messages so I cant find out how much and even if he will ship to the UK. He has it listed for $25, another google site also in the USA quotes $5, but again no shipping details.

I know its a long shot but if anyone can thing of where I can find one?
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grahamd1
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PostPosted: 15:57 - 01 Aug 2012    Post subject: Reply with quote

A big thanks to Aff who has saved the day and found a uk supplier with stock, THANK YOU Thumbs Up
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grahamd1
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PostPosted: 22:56 - 01 Aug 2012    Post subject: Reply with quote

Oil pump now back together (new washer and nut).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0990.jpg

New kick start oil seal installed

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0991.jpg

At this point I've put the side on, with only 3 bolts, I think when I do the timing it might make it easier if I can get this side off and turn the drive as needed.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0992.jpg

And on with the pump cover (off to get some new cheese headed bolts for the cover and counter sunk bolts for the small oil cover tomorrow from my local fastner supplier).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0993.jpg

At this point its worth a reminder of where we started

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0286-2.jpg
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grahamd1
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PostPosted: 19:43 - 02 Aug 2012    Post subject: Reply with quote

Not had a lot of time today, but did get the pistons back in

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0994.jpg

And yes new gudgin clips, new rings

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0995.jpg

Was going to lower the barrels on, then found the thing I kept meaning to order,,,, the damn gasket set, ARGHHHHHH
Now on order from Wemoto
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Aff
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PostPosted: 20:18 - 02 Aug 2012    Post subject: Reply with quote

grahamd1 wrote:
A big thanks to Aff who has saved the day and found a uk supplier with stock, THANK YOU Thumbs Up


No problem. Thumbs Up

Looking forward to seeing the thing finished.
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Hobgoblin
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PostPosted: 23:06 - 02 Aug 2012    Post subject: Reply with quote

Aff wrote:
Looking forward to seeing the thing finished.


+1
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grahamd1
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PostPosted: 16:12 - 03 Aug 2012    Post subject: Reply with quote

Went and saw my mate who owns the car garage, and he's going to loan me his air-fed mask and regulators so I can use 2k paint, bargin.

Went to my local sotckists of paint, and got a 1ltr kit of "red~red~RED" (mixed to match the old red, except I didnt want candy, so nearest to it). So hope to get the fork covers primed and maybe painted over the weekend so I can turn her into a rolling chasis.

Meanwhile picked up all my nice new shiney cheese head bolts and dome nuts for the engine (36 pieces, £5), dome nuts are chrome plated.
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grahamd1
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PostPosted: 18:12 - 03 Aug 2012    Post subject: Reply with quote

Spent an hour with the wire brush and sander to get down to the bare steel (I'd already filled and repaired one of the ears)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0996.jpg

From this (ready now, once the damn winds die to spray the primer on).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0972.jpg
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grahamd1
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PostPosted: 15:40 - 05 Aug 2012    Post subject: Reply with quote

Today I started to put the barrel back on (now I have the gaskets, nuff said on that score), complete with new knock pins

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0998.jpg https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0999.jpg

Starting to lower the barrel on to the pistons

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1000.jpg

another dose of assembly lube, and the pistons move up and down real nice

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1001.jpg

Almost ready to put the top end back on (again new knocks and rubber rings)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1002.jpg
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pepperami
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PostPosted: 18:49 - 05 Aug 2012    Post subject: Reply with quote

You`re doing brilliant Thumbs Up more please Smile
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LongJohn22
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PostPosted: 22:17 - 05 Aug 2012    Post subject: Reply with quote

Very nice work.
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grahamd1
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PostPosted: 19:00 - 07 Aug 2012    Post subject: Reply with quote

DOUHHH major senior moment in the making, guess what I found laying next to the tool box today (hmm wonder why there are two left in the packet), boy do I feel a pratt, still better to find out now than hearing about it later (SCREEEEECH as the engine siezes). Never mind had a dry run.....

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1005.jpg

Cam chain tensioner pushed firmly all the way home into the head.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1007.jpg

Using some flexible steel wire to retain the cam chain in place whilst I lower the head into place.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1008.jpg

So I can remove the wire I put through the chain lower down.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1009.jpg
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grahamd1
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PostPosted: 19:02 - 08 Aug 2012    Post subject: Reply with quote

I've got 3 camshafts and not one of them has the little "o" shown in every manual, so I guess the "o" was only evident on the first runs of the engine, all 3 of my camshafts are 1972~1974 and have the two horizontal lines shown for the CB200 in the Haynes manual, so thats what I using.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1012.jpg

I turned the engine (using spanner on end of crank) till the "T" lined up with the pointer (shown in red)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1014.jpg

When I ordered the new cam chain (endless) I had the supplier kindly break it, and provide me (foc) with a rivet link (I've marked it with orange paint).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1016.jpg

Confirmation when I put the crank on the "T" my two horiz lines are level with the top of the head, and the spigot for the points is at 90deg (up)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1015.jpg

First time I've not used a standard horseshoe quick link, so I guess I now need to nip down the farm and borrow the chain riverter to burr the ends over the link, or something else ?
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grahamd1
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PostPosted: 16:05 - 09 Aug 2012    Post subject: Reply with quote

Meanwhile since theres no wind today and the suns shining, time to play with paint

Rubbed down and filled (two were new, two were old and beaten up) the fork covers and headlamp holders (Ears).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0996-1.jpg

Then primed (I tried hanging them up, but to be honest it was a nightmare, the HVLP gun, although low preasure was enough to blow them back and forth).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0997.jpg

Finally despite the heat (well you put a boiler suit on over your jeans etc on a day when the temp is so high in direct sun light), and near suffocation from the face mask and goggles (safety first), I attempted my first mix/spray of 2K (2 part) paint.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1017.jpg

I wish the camera did it justice, but boy do they shine like new, much better than acrylic paint, and being 2k it doesnt need a clearcoat or laquer over the top, however I noticed now they are dry a few odd places I've missed so no problem, I will give them another blast later. But all in all, very impressed and happy with the finish.

I will take some better pics later outside so you can see the deep glossy shine.
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grahamd1
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PostPosted: 17:33 - 09 Aug 2012    Post subject: Reply with quote

Meanwhile some better pics, and I dont think too bad for my first spray attempt.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1018.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1019.jpg
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Aff
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PostPosted: 17:40 - 09 Aug 2012    Post subject: Reply with quote

They look really good. Can't remember if you said earlier in the thread, but how did you match the colour? I need to try and match my CD200's blue.
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grahamd1
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PostPosted: 18:10 - 09 Aug 2012    Post subject: Reply with quote

Aff wrote:
They look really good. Can't remember if you said earlier in the thread, but how did you match the colour? I need to try and match my CD200's blue.


I took the cleanest example to my local paint supplier (motor trade) and they offered me an exact candy red, but I chose the next closest non candy, that they called red red Red...
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grahamd1
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PostPosted: 19:15 - 09 Aug 2012    Post subject: Reply with quote

I called a friend of mine who runs a motorcycle engineering works, and asked about borrowing (or taking the engine to him) a chain riveter, he chuckled and told me they tend to brake. Instead he explained that most deallers (I confirmed this with a call to another guy I know), use a large hammer on the back of the link (held tight against), and using a small panel hammer (the small one you tend to use to hammer in small panel pins), you tap, tap, tap till you have burred over the pins, sure enough looking at the chain all the existing links are burred over, not riveted as such. So armed with a largish hammer and a small panel hammer I gently tapped away for a few minutes till the pins looked like the other links, I guess they make the pins softish for this reason, they burred over very easilly. The picture was taken looking through a magnifying glass so you can see the burring on the link and exisiting links.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1021.jpg
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grahamd1
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PostPosted: 18:38 - 10 Aug 2012    Post subject: Reply with quote

Onwards ?
Now time to do the headlamp shell (Fglass), I lightly rubbed it down with some fine emery (the sort you get on a thin sponge) all over, then applied the first coat of primer to show up any blemishes.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1022.jpg

This showed up some hairline cracks/splits that I further rubbed down and filled with epoxy and knifing stopper (crack filler), re-primmed and again rubbed down.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1023.jpg

Now I'm ready to mix my 2-part paint (funny takes me longer to suit up put on my mask etc than it does to paint the part!), this time I stripped off (not a pretty sight), and put the cover-all suit on with no jeans/t-shirt, MUCH BETTER.

And here we are

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1024.jpg

I have to say I'm very, VERY happy with the luster/shine that this paint produces (this is after 1hr in the conservatory (full sun) with the doors shut to get the temp up, just to speed up the drying. (now dry).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1026.jpg

Without blowing my own trumpet, I think I've got this paint worried, I might know what I'm doing!!
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grahamd1
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PostPosted: 14:52 - 11 Aug 2012    Post subject: Reply with quote

Valves now adjusted

https://i314.photobucket.com/albums/ll431/grahamdrry/IMAG1027.jpg

Camshaft and rockers lubricated

https://i314.photobucket.com/albums/ll431/grahamdrry/IMAG1028.jpg

Points cleaned and put back on plate, and plate going back into the engine

https://i314.photobucket.com/albums/ll431/grahamdrry/IMAG1029.jpg
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grahamd1
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PostPosted: 19:08 - 11 Aug 2012    Post subject: Reply with quote

OK, a bit more on the frame I thinks

This time the front mudguard (my bike never came with one, but I got this one off Flebay some time ago, they go for stupid prices!!)

https://i314.photobucket.com/albums/ll431/grahamdrry/IMAG1031.jpg

First step, remove the old paint, so on with the nitromors

https://i314.photobucket.com/albums/ll431/grahamdrry/IMAG1032.jpg

As soon as it starts to bubble, I use the same brush (with more on) to brush off and through the bubbling paint (the brush I use came free with "wonder wheels", its a short stencile brush). After a few coats I use a fine wire brush and hand brush off (some times you need to bust the surface of the paint to allow the striiper to get under the paint) the loose stuff.

I found this hole underneath on the front cross member

https://i314.photobucket.com/albums/ll431/grahamdrry/IMAG1034.jpg

And these three holes in the center (between the forks).

https://i314.photobucket.com/albums/ll431/grahamdrry/IMAG1036.jpg

Rather than use Fglass I'm using metal epoxy and fine mesh (I want some strength).

https://i314.photobucket.com/albums/ll431/grahamdrry/IMAG1038.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/IMAG1037.jpg

And now its all rubbed down (I'm going to hamerite the underneath)

https://i314.photobucket.com/albums/ll431/grahamdrry/IMAG1039.jpg

Tomorrow I will apply the first coat of primer so I can rub down the outside and see what the finish will be like.
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