Loooong project CD175

[grahamd1]

Can't believe I spent most of today, rubbing/spraying/rubbing down the front mudguard, BUT I think I now have it worried, but 2 tins of primer later, I still keep finding bloody marks I'm not happy with.....ARGHHHH, tomorrows another day (and I need to get more primer)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1040.jpg

Meanwhile I fitted the speedo (new bulbs), and tested the lights, all work (NOW!!!!)..

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1047.jpg

And a pic with the speedo installed

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1046.jpg
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[Hobgoblin]

as usual quality work graham.

+1
____________________
Plodding along on my CG

[Fazer Tom]

Beautiful
____________________
(CBT 01/07/11. Theory, 21/05/12. MOD 1, 01/06/12. MOD 2, 3/08/12)

Past: (1981 CG125) (1992 ZZR250 x2) (1976 KZ400) (1993 400 Superfour) (2002 Triumph TT600) (1998 Fazer) (2001 CCM 636) (2000 CCM 604) (2007 Kawasaki Z750) (2005 Husqvarna SM450R) Current: (1989 Bandit 400)

[grahamd1]

Spent a while setting up the points (I used a dvm to check when they opened, as an audible indication is easier than by eye or using a bulb).
Checking that they just opened on the "F" mark

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1055.jpg

Then with new gasket in place it was time to close up shop

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1056.jpg

Valve covers installed (new rubbers), and new condensor (bugger me if I didnt have to modify it to fit, so much for "genuine CD175 replacement", and top now torqued down

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1057.jpg
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[CHR15]

the condenser sits on the outside of the engine?
____________________
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.

[Fazer Tom]

[CHR15]

[grahamd1]

[CHR15]

[grahamd1]

[grahamd1]

Time I took a longggg look at the rear mudguard (looks a bloody wreck)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1052.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1053.jpg

The underside (cable route) looks even worse, I struggled to get the cables out and as I pulled the cables great lumps of the cable route came away with them.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1054.jpg

Still its no good being scared of it now is it? Guess its out with the JB Weld and steel mesh then, and lots of time and energy...
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

Before moving on to the repair of the rear mudguard, I spent a few hours today stripping and repairing the fully enclosed chainguard (a key feature of the CD175 that some resorers don't seem to bother with?)

I managed to get another bottom half off Fleabay some months back as mine was just a corroded mess (this one isnt pristine, but its do-able), so my old red top, and a blue bottom (sounds like something you catch if you sit on your arse for too long on the snow).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1058.jpg

As you can see a fair lump of the original metal (the bit that encloses the rear sprocket) is missing

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1059.jpg

Using some body repair ally mesh

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1060.jpg

Add to that some JB Weld, and its as strong as the ally next to it, ready for filing/sanding

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1062.jpg
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[Tomzo47]

absolutely love these bikes, first bike I ever rode, and am seriously considering buying one, but just dont have the space and would have to keep it outside, which is just wrong.
____________________
Ybr 125 > Bandit 650SA > GSXR 600 > Triumph Sprint St1050 > CB1300 > Z1000SX + FJ1200 (written off) > VFR750 >FJ1200

[grahamd1]

[Tomzo47]

My girlfriends dad has a half restored one in his garage which I learnt on, he only needs a few more parts and new tires and it will be ready for MOT, hes got a Jawa CZ to do next so he might be selling me the Honda, just need somewhere to put it
____________________
Ybr 125 > Bandit 650SA > GSXR 600 > Triumph Sprint St1050 > CB1300 > Z1000SX + FJ1200 (written off) > VFR750 >FJ1200

[Fazer Tom]

[grahamd1]

Thanks Tom.

Sun was shining, so out with the paint stripper (nitormors), look out fuel tank its coming your way!

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1063.jpg

Voila, no paint, however that brown muck on the top was like someone had stuck a fibreglass matt to it, but was just rust, but a bugger to remove.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1064.jpg

Having sanded and sanded, and then sanded some more, I liberally applied many coats of spray filler-primer, you can see the matting effect still coming through the filler/primer, so you can see why MORE sanding was needed.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1065.jpg

Then in turn sanded down, re filler-primer and yet more sanding, untill I felt I could put a coat of standard primer on (and now thats being rubbed down with wet/dry)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1066.jpg

the white bits are knifing stopper (filler paste), just got to rub them down and apply a final coat of primer and its good to go.
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

I was looking at some of the pics I took when I first got the old girl out of the boot of my Citroen Picasso (yes the CD fits in there no bother)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0278-1.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1046.jpg

Wow its only when you look back you can see where your going.... (the eagle eyed may notice the speedo is not the original, thats because its not, the original was rusted solid).
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

Meanwhile its Carby time (no stuff the diet), not bad for a carb thats sat around for so long

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0449.jpg

I expected a lot of sticky crud in the float chamber, but nope (someone either drained it, or it leaks)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0450.jpg

Not too bad, but still has to come to bits

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0451.jpg

first parts

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0454.jpg

Now the top end

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0458.jpg

Thats every thing out (jets, floats, air tubes etc)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0461.jpg

Gonna leave it all in a jar of petrol for a few days

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG0469.jpg

The body I will try in my new ultrasonic bath I got a few months back, been dying to try it (I've had mediocre degrees of sucess with the small jewlery ones, but this is a much better 2LTR industrial one with heater, and a couple of litres of carb cleaner).
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

Before it got too hot today, I blasted the first base coat on the tank (not the best of photos but had to go out, so had to rush this one, better ones later).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1073.jpg

More coats tonight, and assembly
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

As they say, "no pain no gain", so whilst the weather is nice I want to get as much paint stripping/painting done as possible.

So I did a job I've been putting off for months, mainly due to the lack of information in both the Honda and Haynes manuals on stripping down the rear shocks, I know I could get some pattern shocks, but NO sorry they look nothing like the correct CD175 shocks (another part of the CD's character), and I have 4 of them to choose from, so I'm hoping to get 2 good at least.
The Haynes and Honda manuals both talk about a split collet, ie compress the unit with the help of someone else, and remove the split retainer!!! the only true picture is the exploded view on cmsl (no retainer). I also trawled the internet and didnt find anyone showing how (or even if) the CD175 shocks being overhauled, so here we go.

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

Part 3 screws into part 10, problem is on all 4 the parts 3 & 10 were stuck solid to part 4 (threaded part), so no way could you depress the unit and undue the parts by hand.
I nipped down to the farm workshop and we all had a headscratching session, and chose to modify a large baring remover (used on combines and large tractors).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1074.jpg

The baring pusher has a course thread and a final 1" fine thread that enabled the device to be compressed enough to be able to get some pipe grips on the part 4, and a leaver in the shock eye (part 3) and it started to come undone.

Once I got the first one to bits I could see how/why to get them apart, but as stated "by hand?" NO WAY....

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1075.jpg

And here is the sum of the parts (even when the 4 were being compressed today, none of them leaked, or showed any signs of not being upto the job).

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1076.jpg

Yes the parts look rusty (so whats new?), but nothing that can't be cleaned, re-painted, and some further testing of the inner shock part. The bonus is when cleaned up and re-greased it should then be possible to put them back together by hand.
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[Hobgoblin]

Great work again graham though we just need

https://diablo.incgamers.com/wp-content/uploads/2012/07/moar_birds-300x240.jpg!!
____________________
Plodding along on my CG

[grahamd1]

Tanks coming along

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1079.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1081.jpg

Still needs rubbing down and polishing
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[grahamd1]

Still cleaning up the rear shocks (wirewool and oil)

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1082.jpg

Managed to get hold of another rear mudguard (fleabay) complete with indicators (handy coz mine didnt have any) and best of all the wiring trunk is in excellent condition, so been spending time breaking it down and stripping off the paint, and fully agree nitromors is now CRAP, doesnt even bubble the damn paint.

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1083.jpg

Meanwhile the tank is done, petrol tap installed, and everything presure tested (Used compressed air via fuel outlet).

Before pic

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1064.jpg

https://i314.photobucket.com/albums/ll431/grahamdrry/CD175/IMAG1084.jpg

Hope to get the rear and front mud guards, and the top of the rear shocks painted tomorrow.
____________________
XV1100, XV750
CD175 (Rebuild)
CF70 (Chaly - Rebuild),

[daverwheeler]

looking good, nice work.