Honda CL90 Scrambler

subrew

New Member
Some details of my latest build:

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I'm starting another project, as the Miyata is 99% done, and I'm ready to build something else. I have had four Honda S90/CL90 parts bikes in the back shed for a couple years, just waiting to become something fun. I've also had a hankering to do up a little 1960s style Desert Scrambler bike. Something stripped down, taller suspension, knobby tires etc. I might even be able to run a Hare Scramble event or two.

He shall be known as "El Guapo":

el%2Bguapo.jpg


I pulled the top end off one of the spare motors, and was pleasantly surprised and how fresh it looked. Just needs a light honing, valve grinding, and a little porting:
engine%2Bdisassembly%2B013.jpg


One of the keys to this build, is getting the right tank. I want something chunky, and bigger than the stock CL90 tank as shown below:
engine%2Bdisassembly%2B014.jpg


I also want the tank to have clean sides, as in no knee pads and spots for emblems. That way I can have plenty of room for a painted tank. Possibly with a Mexican riding a burro. Just my first idea.

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A few updates:

I found a 21" front wheel assembly from a SL125 in excellent condition, complete with knobby 2.75x21 Bridgestone knobby:
stuff%2B015.jpg


I also found some fork boots and a gasket kit:
stuff%2B013.jpg


A little mockup:
frame.jpg


I also found a Hodaka SL250 Thunderdog fuel tank. My goal was to find a big, chunky, beefy tank, and this met that goal. When I first opened the box, I thought I had overdone it. But I think it looks great on the frame:
mockup%2B001.jpg


An idea for a long seat shape:
mockup%2B002.jpg


A short seat with a Honda C100 luggage rack, and a little mockup rear fender:
mockup%2B005.jpg


An idea of what a hardcase (DL1 case) looks like on the back:
mockup%2B007.jpg


I can tell already that will be quite a bit of fab work. Lots of brackets required, likely making an entire new seat pan etc. Should be fun.

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Got a new rear tire mounted, a 3.5x18 trials tire, onto a wider 2.15x18 rim. I've also played with the tank mounting location, and generally cleaned up a lot of parts. I also picked up a pair of Honda XR250 twinshock rear shocks, which have a 16" eye-to-eye length.

Mounting rear tire:
rear%2Btire%2B001.jpg


Rear tire mounted, shock in place:
rear%2Btire%2B004.jpg


Side profile:
rear%2Btire%2B003.jpg


Need to play with the seat mounting location, to get it level with the tank. I also have a simple idea for a rear fender, so I might see if that gets tinkered with tomorrow morning. It has been hot as balls the past couple weeks, so garage time has been limited.

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I haven't been slacking, I've just been doing lots of small things lately on the bike. Including:

Figuring out how long rear shocks need to be, and getting the seat pan mounted:
seat.jpg


Rebuilt a set of Koni shocks from a Honda XR250 Twinshock:
Photo0321-725825.jpg


I made up a set of fenders, using a Hodaka fender as a mold:
seat%2B007.jpg


As mounted on bike. You'll also notice I also worked up a seat, using a cutdown version of a CL90 pan, new foam, and some brown fake leather:
Photo0332-757074.jpg


Detail of front fender:
Photo0333.jpg


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A bit more progress, including footpegs, various levers and brackets, and the exhaust, which I finished up this morning.

exhaust%2B002.jpg


exhaust%2B003.jpg


exhaust%2B004.jpg


A few more sessions of fiddling and fab work, and I might be able to get it prepped for paint.

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Just a quick recap, with some bad night photos. About 20 minutes after these shots were taken, the bike was torn back down to parts in preparation for painting.

cables%2B002.jpg


All new cables run and fit for size:
cables%2B003.jpg


I should have most of the frame parts painted in a couple days. I'm going with an orange frame, and a white tank. Then I can sketch up some tank artwork.

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Paint and assembly. It has been a busy weekend.

Rolling chassis:
car+show+012.jpg


Engine and wiring installed, it has spark first kick over:
assembly+004.jpg


Exhaust, footpegs, misc levers and brackets, controls and bars:
assembly+009.jpg


More:
assembly+010.jpg


Still needs more paint work on the tank. I'm planning some hand lettering in orange, with brown/black outline:
assembly+012.jpg


I forgot to order a new chain, so i did that yesterday. It is getting real close to running.

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Almost done. It has even run for a minute, but I discovered an oil leak. So I took the top end off and made a new gasket. I also got the tank all lettered and outlined. I'm finally getting decent with my pin stripe brushes.

tank+paint+003.jpg


tank+paint+004.jpg


tank+paint+006.jpg


tank+paint+008.jpg


tank+paint+002.jpg


tank+paint+011.jpg


I'm letting some gaskacinch cure up, and will fill it up with oil and see if I cured the oil leak. It did sound great for the short time it was running.

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I spent the day cleaning and organizing the garage:

DSCF3106.JPG


While I had all the bikes out:
DSCF3100.JPG


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I still need to tinker with it a bit, but have managed a few trips around the block on it.
 
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