hI. Because the engine forms part of the frame and is stressed, what used to happen was the top mounting bolts around the cyl head would come loose. Then the engine would only be held only by the rear bolts and it would chatter in the frame and then fail usually on the top pair. Another pending fault with this bike is the fact that the wiring to the alternator runs close to the starter chain it can cut it,and you are a flat battery away from home before you find out,and unless you know where to look it can be a long walk(I Know)
Thanks SOX.. Those will be good things to check. Service bulletins would be a neat thing to have online. Maybe someone has them or next time I'm at a dealer friend I'll try to get them to post. Doubt they are "for dealer eyes only" anymore. Dave
Making my seat... I started with a piece of 3/8" plywood to use as the pan, so I can staple the bottom of the upholstery underneath. I cut it to exactly follow the curvature of the frame. Most of the "pod" will be hollow so I can mount my battery and electrical inside. Loosen 2 wing nuts below, and the whole thing will lift off for battery access. Getting the big blob of spray foam was the hardest part. Ya have to make it in lots of little layers or it falls flat like a big pancake. Don't ask me how I know! I shaped the foam using a serrated knife and a rasp. The idea I have is to give it the same general shape as the tank, especially the curvature of the tail end. A layer of duct tape over the foam so the fiberglass doesn't stick, and i'm ready for 'glass! My first real experience working with fiberglass was a success! But talk about a sticky mess! I used one whole quart-size kit which was three layers of cloth over the entire thing. It's about an 1/8" thick and nice & strong. Once dry I gutted out most of the foam using a drill and 1 1/2" paddle bit. I left about 2" of the foam right at the seat back for added strength. Next up was about 4 evenings of grind, rasp, bondo, rasp, sand, more bondo, sand, bondo, more sanding to get it just right. I didn't get a picture of this final step because I was too excited to get it to my body man for a final glaze and paint! More pictures when it's ORANGE...
Thanks Minnesota Driver! You inspired me to go out and spray some primer on all the body parts I sanded and prepared for paint, oh . . . . about a year ago! I hope I can keep the inspiration going for another evening. More pictures when it's BLACK!
I just sent this in PM to SimpleSimon, who was having trouble with a leaking petcock, but one thing to look out for is that the backside of the petcock handle needs to be flat and smooth. Otherwise it won't seal against the O-ring that you spent money tracking down on Ebay in the rebuild kit. I know this because that exact leak kept me out of a race on my CL175, and the incandescent anger seared it into my brain. <img src="http://www.obairlann.net/reaper/images/avatars/racing04-md.jpg"> That's me racing last year, at Pacific Raceways near Seattle. If anyone's in the area, we've got a race coming up this weekend, and a concentration of 160/175 knowledge like you wouldn't believe. I've also got some (beginner-oriented) videos up on YouTube, some of which are CL175 specific: http://www.youtube.com/results?search_type=&search_query=ianjseattle&aq=f
Whenever I feel like being a slug on the couch, I re-read this thread for inspiration! Feel free to post a new picture of progress now and then for me, and I will do the same for you. My goal for a first ride is June 6th! BTW I got my new title in the mail last week without any problems, even with the ficticious engine number. That was a relief! Oh, and i'm still looking for a right side tank rubber, if you know anyone who can help.
Ahh, the joys of choosing the camera angle carefully! At least the horrible looking runs will be hidden under the chrome panels!
Thanks! Here's a few more pics after some assembly time this evening. Once I had the tank on, I couldn't help myself . . . had to go for a ride. Even without a seat. Or fenders. I have a problem re: instant gratification. The bike runs sweet as a nut!
By the way, I discovered a slick trick when I was reassembling my headlight/speedometer: if your foam-rubber gasket is sun rotted around the part that is exposed, but looks good down in the area that is protected inside the headlight shell, you can turn it inside-out, and reinstall it upside down. That way the nice-looking part that was protected is now exposed under the chrome rim on the speedo, and it looks like you installed a new gasket (which, of course, is no longer available.)
Looking good, Cowboy! I've been spending all my free time polishing aluminum parts. Those wheel hubs will polish up almost like chrome with a little steel wool. Mine had a thick layer of white oxidation, but were like new underneath. Now i need to figure out how to get at the inside of the hubs, between the spokes...
No sense polishing mine much. When it's done, this bike will get used almost exclusively in our pastures and on forest roads. It's going to get abused a bit. (note the trials tires and CL160 skid plate mounted, to keep rocks from breaking the engine case!) I ordered the silver paint for the side covers and fenders. Hopefully the bike will be finished by next weekend. I still need to get busy sewing up a new seat cover.
Here are some pics of my everyday CB160 and my 175 Sloper that was built for the Bonneville Salt Flats. The 160 is pretty stock, new top end, bored +10, rebuilt carbs but all the paint and stuff is original. The sloper is built for top end, I am trying to break 100mph which has not been done by a 4 stroke in the 175cc class. Burnt up a cam at the 08 meet but will be back in 09 with a reground cam and other secret stuff! I also have several other motors and frames which I will build into a full on cafe later this year using the 175 Bonny motor. It always amazes me that you can touch up the top ends of these engines, build the carbs, start them and take off. I recently picked up a superhawk 305 that was made into a dirt tracker in the 70's, it has a custom frame and many other goodys. It has been sitting since 1981 but still turns over! As soon as I finish this years Bonny bike I will start on this one and will post some pics when I get it together. [/IMG]
Here is one of the 175 sloper in it's Bonneville racing form. There are some changes being made for 09, different exhaust, lighter and smaller wheels and tires, small fairing and a smoother back end.