Honda CB160 Restoration Thread

Discussion in 'Old's Cool' started by Cowboy, Jan 19, 2008.

  1. mark1305

    mark1305 Old Enough To Know Better

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    The good news is that since both tabs are broken off, you won't get the buzzy vibes at 9-10K rpm like I did after breaking just one of mine off.

    It's been so long since I've looked inside one of those bikes at the filter lid, that I'm just thinking of the most basic mechanical solution - If the lid is thick enough, drill and tap two holes, maybe 4mm dia or 6mm dia. Put the holes precisely opposite each other on a concentric circle around the lid to avoid balance issues later. Insert bolts or screws into the lid an pull off carefully. Use a puller if needed to exert a straight and controlled force. Or buy some threaded rod the same size as the tapped holes and long enough to bottom out in the filter cannister. Continue tightening them evenly after they hit bottom and they should pull the lid free. Not too much unlike a home made drawbolt/rocker shaft puller I ginned up for the Ducati motors. I can get metric threaded rod from 4mm upwards at my local Ace Hdwe store.

    Then look at how to deal with the screwholes for reassembly. Maybe use some headless allen socket screws like setscrews to plug the holes after removing the new "puller" screws. With a dab of blue Loctite each time.

    The saving grace is that if the lid gets trashed, you could probably have a replacement turned from aluminum flat stock for cheap or by a talented friend with a lathe.
    #41
  2. Cowboy

    Cowboy Ceteris non Paribus

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    I've made some real progress with the CB160 this weekend, culminating in a ten or twelve mile ride this morning!

    I started with my last quandary: how will I get the lid off the oil filter so I can clean it out? I contemplated Mark's idea of drilling it, and making the whole lid into a makeshift puller, by tapping threads into the drilled holes, and running all-thread to the back of the filter. I decided to try again to get it off intact, by prying alternately from one side, athen the next.

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    I was able to work the lid off that way, without causing any damage.

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    There was a lot of dried crud inside, and general evidence that the filter does in fact remove particles of metal from the oil.

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    I had to buy a new shifter, as the original was broken. I also installed new clutch and throttle cables. I was able to free up the old brake cables by pouring light oil down the tubes.

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    Earlier, I had cleaned out the carbs, and reassembled them with their original gaskets, which appeared to be useable temporarily, if only to determine whether the engine had major problems.

    The wiring seems to be intact, with the exception of battery cables, both of which were missing. I snagged a cable off a parts bike and grounded it to the frame to act as a temporary negative cable. I pulled the three-foot long cable off the starter, and ran it from the battery + to the solenoid. I had determined previously that the starter is not working, so my first attempts to start the bike would be with the kick starter. (CB160s had both kick and electric starters)

    After hot wiring the ignition, since I have no key for it, I was ready to give it a try. I checked the points gap, which looked fine as it was. I kicked the engine over with the battery attached, and checked for spark at the points. Good! I checked for spark at the plugs too. Better!

    Time for some fuel now. I ran new fuel hose from the petcock to the carbs, and for the cross-over under the tank. I put the tank back in place, and added fuel. After putting clamps on the petcock connections, the fuel stopped leaking.

    Time to put the exhaust system back in place!

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    Now it's time to fire it up . (Cross your fingers!) It took a bit of hard breathing, and a whole lot of kicks, but one cylinder finally caught. It had a bit of trouble running, as it didn't want to idle on one cylinder. I pulled the fuel bowl from the carb on the left, which wasn't firing. Fuel was the problem. The bowl was dry. I had soaked the petcock in carb cleaner last weekend, but I had apparently neglected to blow air through it, as no fuel was coming through to the left carb. After cleaning out the petcock, I tried again. Success! Both cylinders now fired, though the bike still didn't want to idle. It was late at night, and I decided to wait and look at the carbs in the morning.

    Morning came, and I pushed the bike outside. I gave it a kick, and to my great surprise, it fired right up, and even idled. Not well, mind you, but I'm not complaining! (Elves were apparently turning wrenches on the bike overnight.)

    After fiddling with the idle air adjustment, it ran a bit better. It is a bit noisy, so a valve adjustment and cam chain adjustement are both on the schedule for next weekend. I put the footpegs back on, and took it for a spin around the yard. That went well enough, that I ventured across the road, and tried getting up some speed and shifting through the gears. There is a new development across the road, so I had a good five miles of dirt roads, where the streets wil be laid out in time. No traffic, and the whole place was mine. I rode for a good ten or twelve miles, shifted up and down and generally satisfied myself that this bike runs well enough to justify a larger investment.

    Did I forget to mention that I was smiling ear to ear the whole time?

    [​IMG]
    #42
  3. EvilClown

    EvilClown Reality show stunt double Super Moderator

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    :clap
    #43
  4. mark1305

    mark1305 Old Enough To Know Better

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    Too cool! Glad it's up and running.
    #44
  5. Reverand Roadblock

    Reverand Roadblock nobody

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    I have a '64 CB160 I need to get rid of. It's in fair shape. Motor turns over, tranny gears are rusty. White paint and chrome on tank pretty good. No title. If I can get $200 for it I will be a happy boy. It needs to go because the shop I was storing it in is closing and I don't want to keep it outside. Please someone adopt this poor soul.
    #45
  6. caponerd

    caponerd Kickstart Enthusiast

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    Wow, mine's in better shape than yours. :D

    I can't wait to see how this turns out, I've been putting mine off for years. It's a 1965 CB model with a CL kit installed (bash plate and high exhaust pipes).
    #46
  7. caponerd

    caponerd Kickstart Enthusiast

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    You can't fool me, this is just an excust to show of that gorgeous Chang Jiang (or is it an R11?)

    #47
  8. Cowboy

    Cowboy Ceteris non Paribus

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    Yeah, it's a Chang Jiang. I've gone and bought another since that pic was taken. I took them both out for rides today, enjoying our first warm day this spring. The one in the pic is now a solo bike, most of the time. (the sidecar goes on and off easily) Gutless bikes, but still lots of fun.

    The CB160 project is progressing. I've now mounted new trials tires on it, and ridden it a good thirty or forty miles. I liked it enough that I decided to do a proper restoration and have it ready for summer. The bike is now stripped down to a bare frame. I took the engine to the carwash and it cleaned up very nicely. I have all the sheet metal stripped down, ready for paint as soon as the temps get over 70 degrees F. As a bonus, I scored a skid plate for a CL160 off ebay last week, to make it a bit more suitable for the dirt road riding I enjoy.

    Pics to come when the paint work progresses!
    #48
  9. GIJoeBob

    GIJoeBob Foolish and Inexperienced

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    I have been a recent lurker here and I just joined up mainly because of this thread. I too have a 196? Honda CB160 that I am hoping to restore so I am very interested in your progress.

    [​IMG]

    As you can see the previous owner felt it was necessary to paint a lot of the silver on the bike some puke yellow. Oh well, I'm in no hurry.

    Please keep us posted with your progress!
    #49
  10. GIJoeBob

    GIJoeBob Foolish and Inexperienced

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    #50
  11. Putts

    Putts Gettin' there.

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    Oh heck! This is fun!

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    M'kay, I'm done.

    :lurk
    #51
  12. GIJoeBob

    GIJoeBob Foolish and Inexperienced

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    [​IMG]

    That is what my bike is supposed to look like and hopefully with some work it will eventually.
    #52
  13. Cowboy

    Cowboy Ceteris non Paribus

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    Hey GI JoeBob! Thanks for reviving this old thread! Unfortunately, you've also reminded me of my LACK of progress. Oh well, maybe you'll spur me to get off my butt and finish the bike. Here's a progress report:

    I took the bike to get it registered, and because it came from out of state, I had to have the VIN # inspected. It turns out that the VIN did not match, and I couldn't get the bike titled. All the numbers matched the title, except the "C" at the beginning oc CB160 ####### was missing.


    I decided to restore the bike anyway, and just ride it at home. (I live on an acreage where I could make use of it as a sort of "farm bike") I figured that I might be able to come across a basket case bike in the future with a good title, and then switch out frames. So I stripped the bike down to a nearly bare frame, and started sanding and sandblasting several layers of paint off the frame, tank, stand, fenders and sidecovers. In the course of sandblasting the steering stem, I found the missing "C" in the VIN #, hidden under a run in the paint from an earlier sloppy paint job.

    I haven't started repainting yet, but I plan to do so soon, or else I'll run up against cold weather.

    Putts, are those your old bikes?
    #53
  14. Cowboy

    Cowboy Ceteris non Paribus

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    WOw! that one is even uglier than mine was! Sure makes it easy to feel like you're making progress when they start out this bad!
    #54
  15. GIJoeBob

    GIJoeBob Foolish and Inexperienced

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    Most of it is just dirt, but yeah, I do have my work cut out for me.
    #55
  16. Putts

    Putts Gettin' there.

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    No. I just went rummaging through the internet drawer for a coupla pix. Looking forward to see how yours turns out. :thumb
    #56
  17. eyedragaknee

    eyedragaknee McGuyver

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    #57
  18. GIJoeBob

    GIJoeBob Foolish and Inexperienced

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    You call that a rat bike?!?!? That thing is sweet!

    How 'bout a picture of your Benley?
    #58
  19. Snaildrake

    Snaildrake prowling the SW since '64

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    Not to rain on the parade - I was excited to see a CB160 manual link - but that manual is labeled '72. Those engines are vertical twins, so you'll need a '66-69 manual for the 'sloper' 160 models. ~S
    #59
  20. GIJoeBob

    GIJoeBob Foolish and Inexperienced

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    Argh! Damn you and your facts!! :lol3
    #60