cb350 to cafe' from scratch by a teen

[alonb]

First, let me introduce myself. My name is Alon, I'm 18 years old and I live in Israel. I got into bikes about a year ago, then my dad bought a 99' tj wrangler and the guy who sold us the jeep showed me a picture of his upcoming project, a harley sportster that he was planing to turn into a cafe racer. I immedeatly fell in love with the concept and decided that I was gonna build one myself. I've always loved anything that has 2 (or more) wheels and anything to do with that but my mechanical knowledge isn't that far from changing a tire, naming parts, or how a basic motor works.
And now the bike. I bought a 73' cb350 complete basket case, it was stripped to the frame. The only thing almost complete was the engine (which was a little comforting). I bought it in January and only got started on it now. My plan is to turn it into a cafe racer with a brat-style seat with hidden electrics under it. As for mechanics , I plan to pretty much keep it as stock as possible, without any performance upgrades, because of my little knowledge in bikes. So I just want to get it running with the bare minimum.
That's pretty much it...
I plan to keep this thread updated and upload pics until the very end.
Any help that I get is extremely welcome!!!

 

[deven07]

I for one will appreciate and enjoy your updates. I love seeing the process, and this site has a ton of great inspiration and info on it. I just recently got a '81 Yamaha SR250 given to me, so I'll be dolling her up as well...nothing fancy just for fun! Cheers!

 

[canyoncarver]

Should be interesting. Post plenty of pics along the way. You should be able to find a ton of resources here on DTT.

 

[alonb]

I took apart the top end of the engine, it looks pretty good, not too much wear, it's really clean. I ordered a new full engine gasket kit from dime city cycles and it looks nice, but my only concern is that I've heard a lot that gasket kits are never complete.
My goal with the engine is to split the cases just to check that all the gears are fine and if anything needs replacing. I also bought myself an impact screwdriver, really excited to use it! All the screws on the clutch side cover are stripped. I managed getting only 2 out of 10 loose. I tried everything from dw40 to using a disk cutter. Really hoping that the impact screwdriver works. Here are some photos of the top end disassembly:

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[canyoncarver]

Nice little engine stand. The cb350 is a really popular bike around here. Do you have the service manual yet?

 

[alonb]

Nice little engine stand. The cb350 is a really popular bike around here. Do you have the service manual yet?

I got the Haynes manual from ebay and I also plan to print the Honda service manual.

Also, if anyone sees something wrong with the engine from the pics you're welcome to comment!

 

[alonb]

I finally got the clutch and oil filter side cover off! The impact screwdriver worked like a charm. It unscrewed another 6 bolts, which left me with 2 more that I had to drill, but it's off the engine!
I ordered the clutch & oil filter spanner tool and a digital caliper to measure the clutch springs and etc.
Here are some pics of the clutch cover finally off the engine:

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[alonb]

It's been a while but I got the clutch and oil filter off!

Also, I started the buffing process for the side covers. I first wanted to test out the process on the oil filter cover.
I haven't finished because I need to order the buffing wheels on Sunday and I have another grit level or two to go through. Here are some photos of the sanding process:
What I had to start with:

After 100 grit:

After 280 grit:

After 500 grit:

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[whynot]

I'm on board with this, because I have the exact same engine, doing the exact same rebuild to it too.

Hopefully can give and get pointers.

 

[crazypj]

It's all good until you get a girlfriend (Rocon ;D )
have fun, 350 is great base for just about whatever you want (wouldn't be so good as a fully loaded cruiser )

 

[alonb]

It's all good until you get a girlfriend (Rocon ;D )
have fun, 350 is great base for just about whatever you want (wouldn't be so good as a fully loaded cruiser )

Haha, I've read that thread, great build. And thanks a lot!

I'm on board with this, because I have the exact same engine, doing the exact same rebuild to it too.

Hopefully can give and get pointers.

Hope you're enjoying the build
Would appreciate any help I can get!
And are you also documenting your build?

 

[whynot]

Hope you're enjoying the build
Would appreciate any help I can get!
And are you also documenting your build?

Haven't yet, just collecting parts at the moment........but I guess I need to.

I only have an engine nothing else.

If I come up with a rolling frame at a decent price, I'll consider doing a build.

I have way too many projects going at the moment too.

Truck, needs head 2.4. other truck, spits and sputters at high throttle, cb750 carbs, cb350f paint, cb100, complete rebuild, cb175 rolling frame no engine, cleaning, and cb350 twin engine no frame, plan to rebuild.

 

[Hurco550]

Looking good man. When it comes time to put the lump back together, there are some decent Allen head stainless steel engine bolt kits on the market to replace all the "cover" bolts. They usually are only about $30 or so. Sure beats having to measure and buy them individually IMHO.

 

[alonb]

I was barely home the past month so I haven't got much done till yesterday. I split the cases! It looks pretty "clean". I just need to take out the gears and inspect them and then I can finally start with the rebuild. If there is anything special I should be looking for or if anyone's got any advise, feel free to share. Here are some pics of the splitting procedure:

You can't really see it but I broke three bolts, so I'm gonna have a bit of "fun" trying to get those suckers out...

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[stroker crazy]

Looking good man. When it comes time to put the lump back together, there are some decent Allen head stainless steel engine bolt kits on the market to replace all the "cover" bolts. They usually are only about $30 or so. Sure beats having to measure and buy them individually IMHO.

And don't forget to use anti-seize grease!

Crazy

 

[alzcbz]

What's your plan to replace cam tensioner rollers?

 

[crazypj]

Don't mess around with stock clutch springs.
Even if 'in spec' they are weak and cause clutch slip, get heavy duty/race springs
CB350 in a scooter r different frame could be an interesting project if you can't find a rolling chassis

 

[alonb]

What's your plan to replace cam tensioner rollers?

I've seen lots of threads where people replace the stock tensioner with the KA slipper. I would like to do that but I don't think there's a single guy in Israel who does machining like that. So I think I'll stick with the stock tensioner, maybe get a new one. What do you think of mine, is it still usable or should I get a new one?

 

[alzcbz]

That should be replaced.
I hear there's really not much that needs to be done for the KA. You could use a hand file or dremel.

The small roller is no longer available through Honda.

This may be an option as well:
http://www.dotheton.com/forum/index.php?topic=65197.0

 

[alonb]

That should be replaced.
I hear there's really not much that needs to be done for the KA. You could use a hand file or dremel.

The small roller is no longer available through Honda.

This may be an option as well:
http://www.dotheton.com/forum/index.php?topic=65197.0

I'm going to consider buying a "new" one, it sounds like the best option. Thanks for the advise!

Now for an update:
The engine is completely apart! I got the crankshaft, gears and shifting forks out of the top crank case.

I also have a question for you guys, what do you think of my camshaft, rockers and pistons? Are they ok to use or does anything need replacing?

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