'77 CJ360T (Café SOS) - Calling it Done (for now...)

Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

Dymass said:
That, mister, is the most beautifull seat ive ever saw in my life!
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Thanks, man. :)

It started life as an Interceptor seat from Roc City, but I had to cut it down to fit my 360 (the Interceptor is designed for the CB750). I took about 2" out of the middle and another 4" from the front and glassed the whole thing back together.

The upholstery was done by a friend up in Portland.
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

Do you have a generation 1 interceptor seat? I've got the interceptor seat and didn't change anything on my 360.

Great upholstery on that seat!
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

I didn't really know there were different generations but mine was definitely too large to fit. It would have overhung the frame by almost 2" on each side.
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

Well, I got the engine all buttoned up this weekend. I annealed my copper gasket, got everything into place, torqued down all bolts. I set the valve lash and got ready to check to see how retarded by cam was.

It turns out that I'm the retarded one. After turning around back to the work bench I noticed a very nice looking set of piston rings sitting there.

On the plus side, I get to take the top end apart again. It's kinda like saying goodbye to and old friend with no idea of the next time when you were going to see each other only to find out their flight was cancelled and they'll be sticking around a while longer...

Clearances between valve and piston are between .081" and .092" for the four valves at TDC. According to the timing card, the intake valves are open .048" and the exhaust valves are open .042" at this point and so I have about a millimeter of clearance. It's still a little bit on the thin side (for exhaust at least), so I'll have to be pretty careful not to miss any shifts.
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

Sonreir said:
It turns out that I'm the retarded one. After turning around back to the work bench I noticed a very nice looking set of piston rings sitting there.
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After reassembling the top end of my CB450, I stood back to smoke a cigarette, all proud of myself - and as I reached for the ashtray, I noticed that I had set it down earlier inside the nearest round thing about the same size...the o-rings that go around the cylinders...

Eh, it was easier to put the head on the second time...
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

It's kinda like saying goodbye to and old friend with no idea of the next time when you were going to see each other only to find out their flight was cancelled and they'll be sticking around a while longer...
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HAHAHA!!! THAT is very funny!! I'm very happy that you got to see your old friend again. Saying goodbye can be so bitter sweet Sonreir but sometimes mate, you just have got to let go...

On a different topic, an interesting thing I've noticed with a lot of you american guys is the way you can seamlessly switch between imperial and metric measurements without giving it a second thought!

Clearances between valve and piston are between .081" and .092" for the four valves at TDC. According to the timing card, the intake valves are open .048" and the exhaust valves are open .042" at this point and so I have about a millimeter of clearance.
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0.08"? 0.092"? What is that gobbledegook? Millimetre? Ahhh now you're talking! Time to say goodbye to imperial guys, join the rest of us in the metric world!! :) :) :)
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

OK... I'm pretty eager to finally get this thing on the road (maybe even for this coming weekend?) and so I spent some more time in the shop last night getting things put together.

I got everything reassembled (I even remembered the piston rings this time) and set the lash at zero before checking my valve timing. It looks like I'm advanced by 15° plus a little bit. I was expecting to see things running a bit retarded with the .020" that was skimmed from the head and so I'm thinking I missed a tooth on the cam. If I correct that, it will retard my valve timing by just over 20° leaving the total change at around 5° or retard.

Does 5° sound about right for .020" decked off?
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

sounds about right, mine was 7 deg.
I've over advanced by a further 7 deg , it's easy to retard back to stock if I need to
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

I'm done for the night. I need to hook up the fuel lines, add some oil, and then check the timing and I think that may be it.

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Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

Good job! :) :)

Bet you can't wait to start this puppy up.
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

Nice work my man, I like your paint scheme alot! sure your looking forward to twisting the throttle! looking forward to some sweet day pic's.............
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

Last night I installed new Tygon fuel lines. If you haven't had an opportunity to use this material yet, I highly suggest it. It's extremely flexible and doesn't easily kink or collapse the tube and so you can make some pretty tight angles with the stuff. I removed my old rubber fire hoses and significantly shortened by run. I can't say I'm a huge fan of the color, but it's functional and I didn't feel like waiting on the mail for a set in gray.

I also finished fabbing up a rear "fender". I have a few sheets of 6"x12" brass than I riveted together with a bit of offset in the middle rivet so as to give it a slight curve. I then cut the top and bottom corners to round that out as well. It should help to keep additional debris out of the stacks.

Tonight I'll clean things down with some alcohol and touch up the paint where I scratched and dinged it after assembling/disassembling the top end a dozen times.
 

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Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

Bejesus just fire the damn thing up .......... I'm constantly checking your rollerfreakingcoaster epic from the other side of the planet just hoping to hear that you've actually got a runner on your hands!
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

Bejesus just fire the damn thing up .......... I'm constantly checking your rollerfreakingcoaster epic from the other side of the planet just hoping to hear that you've actually got a runner on your hands!
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Haha!! This is hilarious! Can't say I don't totally agree with the sentiment though!
 
Re: '77 CJ360T (Café SOS) - Assemble, Measure, Modify, Repeat

lol... I thought everyone got bored and stopped reading back on page 20.
 
Re: '77 CJ360T (Café SOS) - Almost There (Stay on Target)

Everything got put back together on Saturday and I started the bike up. It took a few kicks but it eventually got going.

On the down side, it was only running on the left cylinder and the idle was hunting. I suspected my old friend the vacuum leak had reared his head once more and so I took the carbs back off the bike and looked things over. The problem was pretty obvious and so I put everything back together again but opted to include manifold gaskets this time.

I haven't had time to fire it up again since that change, but I also have a very respectable oil leak coming from the right crank case and so I'll tackle that issue before I go too much further.
 
Re: '77 CJ360T (Café SOS) - Almost There (Stay on Target)

dang that seat looks fly....
 
Re: '77 CJ360T (Café SOS) - Almost There (Stay on Target)

Sonreir said:
The problem was pretty obvious and so I put everything back together again but opted to include manifold gaskets this time.
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Cafe SOS lives up to it's name ;)
 
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