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Author Topic: '77 CJ360T (Café SOS) - Calling it Done (for now...)  (Read 99378 times)

Offline Sonreir™

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Hey all,

I'm two weekends into my first build and things (I hope) are going well.  Obviously, I started out with stripping down the bike to the frame and taking everything apart.  Most everything went well.  I did encounter a lot of metal dust when I removed the front sprocket cover and I'm still trying to figure out the reasons.  At this point, I'm leaning toward my poor chain maintenance (haven't lubed it in a while).

I also had a bit of trouble getting the oil plug out.  I ended up rounding off the corners and had to use a set of vice grips to finally get the damn thing out.  So now I'm in the market for a new 17mm bolt.  ;)

« Last Edit: Jun 01, 2012, 01:16:12 by Sonreir »
Sparck Moto - http://www.sparckmoto.com

Audaces fortuna iuvat.

1977 Honda CJ360 - Café SOS - Stage One™, Café SOS - Stage Two™
1976 Puch Maxi - APuchalypse Now

Custom Gauge Graphics
Custom Wiring Harnesses

DTT Red, White, and/or Black 360 Club - Better than those Blue guys

Offline Sonreir™

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Re: '77 CJ360T Café Build
« Reply #1 on: Oct 27, 2010, 14:16:42 »
Anyway... after three hours of the first weekend I got myself to this point:









« Last Edit: May 09, 2011, 12:30:54 by Sonreir »
Sparck Moto - http://www.sparckmoto.com

Audaces fortuna iuvat.

1977 Honda CJ360 - Café SOS - Stage One™, Café SOS - Stage Two™
1976 Puch Maxi - APuchalypse Now

Custom Gauge Graphics
Custom Wiring Harnesses

DTT Red, White, and/or Black 360 Club - Better than those Blue guys

Offline Sonreir™

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Re: '77 CJ360T Café Build
« Reply #2 on: Oct 27, 2010, 14:21:24 »
This last weekend, I finally got the front wheel and forks off.  I also removed the swingarm and started grinding with my angle grinder.  All non-essentials have to go.

So far, I've removed the helmet hooks, center stand mounts (mostly), and two of the three battery box mounts.  Still up on the chopping block are the rear footpeg mounts, airbox mounts, and seat mounts.

From the swingarm, I've removed the chain guard guide and the zerk fitting (PO welded the damn thing shut so I just removed it).







« Last Edit: May 09, 2011, 12:32:08 by Sonreir »
Sparck Moto - http://www.sparckmoto.com

Audaces fortuna iuvat.

1977 Honda CJ360 - Café SOS - Stage One™, Café SOS - Stage Two™
1976 Puch Maxi - APuchalypse Now

Custom Gauge Graphics
Custom Wiring Harnesses

DTT Red, White, and/or Black 360 Club - Better than those Blue guys

Offline IndieSol

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    • Project: Pariah
Re: '77 CJ360T Café Build
« Reply #3 on: Oct 27, 2010, 18:50:25 »
Hey, Sonny.  Hope things are going well.
BMW R100
XT350
CJ360 Cafe Project

Project: Pariah

Offline Sonreir™

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Re: '77 CJ360T Café Build
« Reply #4 on: Nov 01, 2010, 14:11:19 »
OK.. more work done over the weekend. I've ground more stuff off of the frame. Gone now are all of the air box mounts, both seat mounts, and the rear fender guides. Still to go is the front battery box mount and possibly the entire part of the frame with the rear footpeg mounts. I'm a bit nervous about that last section though as I can't remember what (if anything) else gets attached to that part of the frame except the rear footpegs. There's some hols there but I can't remember if they're just for the exhaust or for something actually important. Anyone have some pics of the rear right side of their 360 they can post?

Anyway... I cracked open the engine and the head is now removed. Most everything looks good, but I haven't specced any of it. The rocker arms on the left side look they're quite worn, but the ones on the right seem just fine. Oil starvation? Also, the inside of the cylinders seem OK, but I won't know for sure until I get everything fully dismantled. The valves are different colors between the two clyinders. Was one side running rich or was the other lean?

Finally, the rest of the engine teardown is on hold until I can locate a tool to remove the nut that holds the oil filter in place. I'm looking at ebay right now to get one.

Thanks,
Sonny
Sparck Moto - http://www.sparckmoto.com

Audaces fortuna iuvat.

1977 Honda CJ360 - Café SOS - Stage One™, Café SOS - Stage Two™
1976 Puch Maxi - APuchalypse Now

Custom Gauge Graphics
Custom Wiring Harnesses

DTT Red, White, and/or Black 360 Club - Better than those Blue guys

Offline Sonreir™

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Re: '77 CJ360T Café Build
« Reply #5 on: Nov 01, 2010, 14:12:03 »
Just more pics.
Sparck Moto - http://www.sparckmoto.com

Audaces fortuna iuvat.

1977 Honda CJ360 - Café SOS - Stage One™, Café SOS - Stage Two™
1976 Puch Maxi - APuchalypse Now

Custom Gauge Graphics
Custom Wiring Harnesses

DTT Red, White, and/or Black 360 Club - Better than those Blue guys

Offline IndieSol

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    • Project: Pariah
Re: '77 CJ360T Café Build
« Reply #6 on: Nov 01, 2010, 18:02:50 »


Foot pegs and muffler.  Excellent progress so far.
BMW R100
XT350
CJ360 Cafe Project

Project: Pariah

Offline Sonreir™

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Re: '77 CJ360T Café Build
« Reply #7 on: Nov 01, 2010, 18:45:46 »
Indie,

Do you have a bigger pic?  If not, can you please confirm something for me?

In the attached picture, is the only thing mounted to the circled section of frame is the exhaust and the rear foot peg?
« Last Edit: Nov 01, 2010, 19:35:19 by Sonreir »
Sparck Moto - http://www.sparckmoto.com

Audaces fortuna iuvat.

1977 Honda CJ360 - Café SOS - Stage One™, Café SOS - Stage Two™
1976 Puch Maxi - APuchalypse Now

Custom Gauge Graphics
Custom Wiring Harnesses

DTT Red, White, and/or Black 360 Club - Better than those Blue guys

Offline IndieSol

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    • Project: Pariah
Re: '77 CJ360T Café Build
« Reply #8 on: Nov 01, 2010, 18:47:12 »
That's correct.
BMW R100
XT350
CJ360 Cafe Project

Project: Pariah

Offline belch_brother

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Re: '77 CJ360T Café Build
« Reply #9 on: Nov 01, 2010, 19:18:36 »
This is a cj250t but its the same setup.. indie is correct.

honda_cj_250_t_1977_4 by belch_brother, on Flickr

Offline Sonreir™

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Re: '77 CJ360T Café Build
« Reply #10 on: Nov 01, 2010, 19:33:09 »
Sweet.
Off it goes, then.  :D
Sparck Moto - http://www.sparckmoto.com

Audaces fortuna iuvat.

1977 Honda CJ360 - Café SOS - Stage One™, Café SOS - Stage Two™
1976 Puch Maxi - APuchalypse Now

Custom Gauge Graphics
Custom Wiring Harnesses

DTT Red, White, and/or Black 360 Club - Better than those Blue guys

Offline belch_brother

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Re: '77 CJ360T Café Build
« Reply #11 on: Nov 01, 2010, 19:40:44 »
Uncle chop chop... (Aussie movie 'Chopper' reference)  ;D

Be interesting to see the frame without those back hoops!

Offline Sonreir™

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Re: '77 CJ360T Café Build
« Reply #12 on: Nov 08, 2010, 13:49:30 »
Got a good deal of work done this weekend. Just about finished with all the grinding on the frame. Only the front battery box mount is left. I'm worried about being able to fit the angle grinder in that tight space as I don't want to screw up the gas tank mount (which appears to be two different parts of the same chunk of metal). I may wait and see if I get a Dremel tool for my birthday. Am I going to need to smooth all these grinds out before they go to the powder coaters or can they lay it on thick enough to where it won't be noticeable?

Also, the engine is almost completely disassembled and I'm pretty certain I found the cause of the top-end noise I was getting. Only things left to remove are the kick starter and the valves + springs. Is there a special tool needed for the valves? A spring compressor or something? Because I can't see a way to do this without losing a finger.

I've also started polishing some of the engine components up, but I think I've made a bit of a rookie mistake... I started with sanding wheel attached to my drill and I think it's taken off too much metal. I've spent about 45 minutes now using 150 grit by hand and I think I'm still hours away from removing the initial tool marks from the drill. Would I be OK dropping down to a coarser grit? 60 or 80 or something like that?
« Last Edit: Nov 08, 2010, 13:51:34 by Sonreir »
Sparck Moto - http://www.sparckmoto.com

Audaces fortuna iuvat.

1977 Honda CJ360 - Café SOS - Stage One™, Café SOS - Stage Two™
1976 Puch Maxi - APuchalypse Now

Custom Gauge Graphics
Custom Wiring Harnesses

DTT Red, White, and/or Black 360 Club - Better than those Blue guys

Offline Sonreir™

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Re: '77 CJ360T Café Build
« Reply #13 on: Nov 08, 2010, 13:50:15 »
And some more pics.  :)
Sparck Moto - http://www.sparckmoto.com

Audaces fortuna iuvat.

1977 Honda CJ360 - Café SOS - Stage One™, Café SOS - Stage Two™
1976 Puch Maxi - APuchalypse Now

Custom Gauge Graphics
Custom Wiring Harnesses

DTT Red, White, and/or Black 360 Club - Better than those Blue guys

Offline Sonreir™

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Re: '77 CJ360T Café Build
« Reply #14 on: Nov 15, 2010, 12:58:41 »
Well.. a little more progress made.  I spent most of my work time this weekend getting the stator cover polished.  As I'd mentioned earlier, I put some pretty nasty scratches into the cover this last weekend by starting with power tools.  :(  Nothing three hours of hand-sanding couldn't cure though.  I finished my last sanding with 1500 grit paper and I'm ready for the buffer (once I get one).

I also did a bit of research into new cams and rockers and have some info to report.  I found a place in California (MegacycleCams) that will regrind my core and increase the duration to 251°.  They recommend that I use modified pistons and springs though, so I'm following up with them to see exactly what that means.  I was also able to find OEM rocker arms for about $40 a piece (my Mom's husband works in the business and was able to get a good deal), but I'm going to hold out for now to see if I can get something with a bit more lift...
« Last Edit: Nov 15, 2010, 14:23:47 by Sonreir »
Sparck Moto - http://www.sparckmoto.com

Audaces fortuna iuvat.

1977 Honda CJ360 - Café SOS - Stage One™, Café SOS - Stage Two™
1976 Puch Maxi - APuchalypse Now

Custom Gauge Graphics
Custom Wiring Harnesses

DTT Red, White, and/or Black 360 Club - Better than those Blue guys