CB160 - First Build (AKA - Born at Brewer's)

[cafepenguin]

And it begins....

Hello, so as the heading states, this is my first build and it is a CB160. The Born at Brewer's is because I picked it up at Brewer's Salvage Yard in Los Angeles. And it is going to be a lot of work. I have attached a photo below. There is a lot of rust and a lot of dust to be cleaned. And I won't be getting to most of this for about a week, because my girlfriends dad is in town till next Sat.

Some things to happen... (I plan to get it running before doing any cosmetics)

First, the Engine - The guy at the salvage yard said it was locked up, so I'm planning on pulling it apart and checking everything out and doing a good cleaning. I know everyone says that cracking the case is not good if you don't have to, but from what I can tell on this so far, it looks like that is something I'm probably going to have to do? Any suggestions on what I should try first? Right now, it does not seem to kick over. Also, I don't want to invest too much in any other parts till I know I can get the engine up and running. I'm sure I will have a lot of questions on this once I get into it.

Other than the engine....

Carbs pulled, cleaned and rebuilt.
As you can see the air filters are toast, so I will be replacing with pods
Clubman bars.
Sanding and polishing of... well a lot.
New Throttle, Brakes and Clutch cables.
All new wiring.
New gasket and oil seals everywhere.
Tank is rusted on inside, and I've seen a few methods on here about cleaning, but...
(WHAT IS THE FAVORITE METHOD FOR CLEANING THE INSIDE OF TANK)
Also, it looks like bottom of tank is starting to rust. (Should I steel wool and black primer the bottom?)
I'm thinking I will probably have to buy new spokes.
New brake pads in front and rear
New tires (What would you suggest?)
Seat (I love the classic cafe style for these bikes)

I know there is a lot more I have not even mentioned so far, but those will come down the line.

I'm planning on taking my time on this build, though I would also love to have it up and running of course.
Anyone have any thoughts or suggestions for me?

Thanks for your time and I look forward to everyones input... This site has been a great inspiration for me already.

 

[copperlite]

Everyone has their own methods...

If the tank is heavily rusted - I've had really good luck with using the electrolysis method [Google it]. I've also had really good luck with the POR-15 tank sealer kit.

If Just the top-end is locked up you probably won't have to split the cases. Try to free it up it with the engine in the bike. Remove the spark plugs, spray a good penetrating lube into the cylinders, let it sit a day or so, then rock the bike back and fourth with it in gear. Repeat the process every day and cross your fingers. When I got my CB160 the clutch plates and friction disks were stuck together so you couldn't disengage the clutch. Just pull the assembly apart and dunk each component in fresh oil before reassembling.

Are you planning on getting it running and working on it while you ride or a doing complete tear-down?

 

[Big R]

Cool scoot - glad to hear it found a new home. In the "Build Collections" area, there is a thread I started just for the small Honda's. Aside from links to build threads, there are links to some good info as well.

 

[cafepenguin]

Hey Copperlite-
Thanks for the input. I will take a look at the POR-15 sealer kit. I was wanting to seal the tank, once I cleaned it. I had seen RED KOTE on DimeCity and considered that, but I'll take a look at POR first. And yeah, I may be doing the electrolysis route, because the inside looks to be pretty rusted... And I'm planning on doing a complete tear down of the bike and then putting it back together with all the mechanicals working and the electrics replaced. Drive it for a bit, then make the decisions on the paint and other cosmetics of everything. I also bought the bike to be a learning experience. I have a 500 four but didn't want to learn on the bigger engine.

Big Rich-
Thanks for the heads up on the "Small Honda's" section. There is going to be some great info in there for me. I figured I would respond to the regulator question here to keep it all on one page...

So I'm glad to hear that I can put one on the bike... I'm thinking of getting one of the Regulator/Rectifiers from here...
http://www.oregonmotorcycleparts.com/VRRPM.html
specifically the VRRPM2-HCB for $93. I think that one will work.
Has anyone ordered from them before?

So my girlfriends dad has other plans tonight, so I'm taking the time tonight to build a small work bench in my 5'x5' work space I'm going to be working on the engine in.

Any work to the frame is going to be done in front of my car in the community parking garage at the Apartment, and then all engine work and carb work and well, anything that I can take off will be done in my small storage room that I have. Can't wait to get claustrophobic in there and get to working...

 

[cafepenguin]

So... I've made a little progress. I built myself a work bench in my small storage shed and I can already tell how much fun it is going to be in there...

First, tank, and seat came off.

Next I pulled the carbs and the exhaust pipes/mufflers and the motor. Then I pulled the headlight bucket off...

And now I"m ready to start taking the engine apart... And this is where I ran into a little issue... I'm about to search the engine section, but does anyone have a good recommendation getting the cylinder head off? It seems to really be stuck. I've tried spraying WD-40 on it and hoping that will loosen it all up, but is there something else I should be trying. Along with that, the right and left crankcase covers?
What would you recommend to get those off, since they seem to be stuck as well? The screws have all been impact driver loosened, but the gaskets I think are stuck to the cases... Thoughts/Recommendations? And the Tappet covers... same issues and I don't want to muck those up.

Thanks in advance.

 

[Big R]

What part of the cylinder head? The pistons are stuck in the cylinders, the gaskets are "gluing" everything together, etc?

Usually a couple delicate hits with a rubber mallet can separate sticky gaskets. And wd-40 isn't much of a penetrating fluid (it stands for Water Displacement).

 

[cafepenguin]

Hey Rich,

It's the cylinder head cover. The very top. I took all the cap nuts off and then tried lightly tapping it with a rubber mallet. No go. I tried hitting it a bit harder with the rubber mallet and still no go.

This thing was sitting out in the elements for a few years, so I'm not sure what all is holding it together.

I do have some Liquid Wrench. Should I try spraying that around there, or would Carb Cleaner spray be good to shoot around the edges?

 

[56_oval]

I'm fairly certain the valve cover is just glued on. Try a flathead and see if it pries off. Is the motor locked up?

 

[cafepenguin]

Hey 56

Just saw that you responded on here. I haven't updated in a while, like I should. I need to get a few new pics up and what not...

The cylinder head cover is now off. The pistons were stuck, but I just recently got those free and now I just need to get the cylinder jug freed from the crank case. It seems to be glued down as well. I think I have a method that is going to work. Plan to try that soon, though I'm about to be back in Dallas for a week, so it may have to wait till I get back.

But I need to get the pistons out to see if there is any chance to clean them and the cylinders or if I need to buy some new ones and do a bore job. I'll post some pics once I have them out in order to get some advice on what to do.

 

[clem]

I recently bought a CB160 also. I pulled the right cover off to clean the clutch plates that were stuck. What made that tight was one of the dowels was rusted and therefore causing it to hold the cover and cases together. Lube may have worked but I didn't know that was going on until it was removed. I just tapped with a rubber mallet, pryed with a dull chisel on the outer part of screw holes and went slowly. It was worth the time taken because I didn't mess anything up. Good luck with the project.

 

[legendary_rider]

I love the look of the 160. I bought a 160 tank that I'm eventually gonna try to fit on a 350 or 360. Pretty good shape but I paid a lot for it (200).

 

[56_oval]

If the rings were rusted to the bore, which is common on these early twins, then you will probably need to go up a size or two in pistons. Am I correct in thinking they both move freely in the jug? Or are they still frozen? A diesel bath will free them if you let it sit for a while. If they're loose already, them I'd think it is just some sealant sticking it down. Use a rubber mallet to break it loose, just be careful with the fins.

 

[cafepenguin]

Thanks for all the input and suggestions guys.

I got the cylinder jug off Monday night. Clem and 56, it took exactly what you said. I just carefully pounded it with a rubber mallet and it eventually broke free. The cylinders look to have a little rust on them, so I'm planning on getting the pistons off the arms and taking them and the jug to a shop and asking their opinion. If they tell me all I need is new rings and to hone the cylinders, that would be great, but if not, and if I need to buy new pistons, then I am thinking up upgrading to a set for a CB175.

Legendary_rider, yeah, the tank is one of the main reasons I fell in love with this bike. And yeah, the tanks go for quite a bit on ebay. I'm still looking for a better set of the chrome panels, as mine have some rust pits... but yeah, love the tank on this bike. I'm really looking forward to getting this thing road worthy, but I feel like it may still be a bit down the line. I still need to get the frame and misc. parts powder coated.

 

[legendary_rider]

I've been doing chrome powder paint on some stuff. Doesn't look as good as chrome but pretty decent. More like polished aluminum. There's also a post on here where a guy powder the sides in a gun metal grey. Looked cool. Might be worth considering instead of forking out more bucks. You can always replace later too if not happy.

I was talking to a gent about how to get pistons moving on a motor. He puts hockey pucks in cylinders and bolts down the cylinder studs somehow to press pistons out. Sounded pretty cool.

 

[timbutterfield]

how is the build coming along?

 

[cafepenguin]

Hey hey...

Not a whole lot of new info on the build. I was out of town for a few weeks visiting family, but right before leaving, I managed to get the pistons freed and got the cylinder off the block. But I have not had any time to get back at it, since I got back. But Hopefully either this weekend or next week, i will start back in on it. I have ordered a few things I needed, like a new center stand, since mine was bent. Now I have all the pieces I'm thinking of powdercoating. Anyone ever try powder coating the tank and headlight bucket? I'm thinking since I'm taking the frame the gloss black color, I could go ahead and throw the tank in there as well, since I was thinking gloss black for that as well... save me some time, if they are willing to just throw it in there without extra costs...

 

[timbutterfield]

Never heard of powdercoating a tank

 

[clem]

Glad to hear that you got everything loose. If you go the powder coat route, make sure you get a good coater as it can be a pain to deal with if not done properly. Peace

 

[cafepenguin]

Well now I'm thinking the rattle can way for the tank and the other bits... but the problem is I live in an apartment, and spray painting on my balcony is not a real good idea... so I'm going to have to find a friends house that I can do this at... I know there are several threads on here regarding well to do rattle can jobs... anyone ever done one that they liked best?

 

[Finnigan]

I love the look of the 160. I bought a 160 tank that I'm eventually gonna try to fit on a 350 or 360. Pretty good shape but I paid a lot for it (200).

I'd really like to see that, was thinking of doing it myself