Honda CL450 resto

Discussion in 'Old's Cool' started by johnnyc14, Dec 20, 2008.

  1. johnnyc14

    johnnyc14 Been here awhile

    Joined:
    Mar 8, 2008
    Oddometer:
    205
    Location:
    St. Albert, Alberta
    Well, I have a couple of weeks off and decided to get at my CL450 resto project. I've been collecting parts for 2 years now and I think I have 90% of what I need. Here's some pics.

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    Frame bead blasted and painted with epoxy paint


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    Engine on the Stand, note the oily left exhaust port

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    Cylinders are pretty worn out but I have o/s pistons and rings.


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    Crank and trans are like new.

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    Lots of spooge in the sump, taking these parts to work for cleaning in the Storm King.



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    Big pile of parts

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    I hope to be riding this in the spring
    #1
  2. CZRIDER

    CZRIDER Adventurer

    Joined:
    Nov 13, 2008
    Oddometer:
    21
    Nice!!! Love those old Hondas!!!!
    #2
  3. MNellis

    MNellis Been here awhile

    Joined:
    Nov 5, 2008
    Oddometer:
    127
    Location:
    Georgetown, TX
    That looks great just the way it is. After I'm done with my '68 CL350 I'd like to pick up a CL 450 as well.

    Nice bike.
    #3
  4. johnnyc14

    johnnyc14 Been here awhile

    Joined:
    Mar 8, 2008
    Oddometer:
    205
    Location:
    St. Albert, Alberta
    Thanks guys, the biggest reason I took it apart was the sick engine, low compression on the left cylinder. Then I got the bug and decided to go through the whole bike.
    #4
  5. Doug Matson

    Doug Matson Long timer

    Joined:
    Aug 25, 2003
    Oddometer:
    2,376
    Location:
    Torrance, Ca.
    I remember test riding the first 450 that came into So Cal when I was in high school. It was a CB and thought it was huge compared to my CB160, it was. The CL was so much nicer looking, CB tank was ugly! Nice bike.
    #5
  6. AlfromMI

    AlfromMI Long distance nut

    Joined:
    Aug 27, 2007
    Oddometer:
    126
    Location:
    SE Michigan
    My first big bike was a 1968 CL450 that I bought brand new. I really liked that bike, I still think it is a very good looking motor. Way back then, a 450 was a big bike, nowadays, it's a tiny starter bike.:D
    #6
  7. johnnyc14

    johnnyc14 Been here awhile

    Joined:
    Mar 8, 2008
    Oddometer:
    205
    Location:
    St. Albert, Alberta
    Well, I got the cases split and took the parts to work and put them in the Storm King parts washer to get all the spooge off them. They are clean now but still look like 40 year old aluminum si I decided to paint them. I used Duplicolor engine enamel in Aluminum color as recommended by some folks on the Hondatwins site.

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    #7
  8. anonny

    anonny What could go wrong?

    Joined:
    Mar 20, 2007
    Oddometer:
    5,776
    Location:
    Beautiful Revelstoke BC
    Nice project.... by far one of the best to come out of Japan
    #8
  9. johnnyc14

    johnnyc14 Been here awhile

    Joined:
    Mar 8, 2008
    Oddometer:
    205
    Location:
    St. Albert, Alberta
    I got to spend some time out in the garage today. I had repair the chain guard that had some cracks.

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    First I enlarged the cracks with my disc grinder and a 1/8" cutting disc.

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    Then I mig welded the grooves closed.

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    Then a little grinding and sanding, it looks like new again. At least it will after a couple of coats of paint.

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    #9
  10. johnnyc14

    johnnyc14 Been here awhile

    Joined:
    Mar 8, 2008
    Oddometer:
    205
    Location:
    St. Albert, Alberta
    I got the frame mounted on my bike lift ready to start some assembly.

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    The previous owner had taken a hammer to the brake pedal for some reason and it looked very rough. I would like to stick with the CL brake pedal just because it's different. Even though I have a really nice CB pedal I decided to try to fix the CL one. It's hard to see in the pic but the shaft bore in the pedal was pounded so the shaft would not go through and the shaft itself was also very beat up. The shaft measures 19mm so I took a piece of 3/4" electric motor drive shaft I had and used it as my new pivot shaft. I used a 19/64" drill bit and my drill press to restore the bore in the pedal. This provide 1/64" clearance between the new shaft and the pedal bore.

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    I cut the shaft to length and drilled a hole for a cotter pin in one end and welded a washer to the other to act as a shoulder for the brake pedal.

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    I also made up a pedal stop with a rubber bumper so the pedal will not clank into the frame when released. I glued the rubber bumper to the nut with grip glue.

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    A little more bead blasting and paint and I can mount this stuff on the bike.
    #10
  11. johnnyc14

    johnnyc14 Been here awhile

    Joined:
    Mar 8, 2008
    Oddometer:
    205
    Location:
    St. Albert, Alberta
    I disassembled the forks and cleaned out all the sludge and replaced the seals. Filled them with 150cc of 10wt fork oil in each leg. I polished up the lowers and then reassembled. I got the triple clamps mounted and installed the forks and headlamp ears.

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    #11
  12. Cogswell

    Cogswell Spudly Adventurer

    Joined:
    Jan 3, 2005
    Oddometer:
    4,787
    Location:
    Riding with my pal Richard Cranium
    :lurk

    Good Stuff, keep it coming. :thumb


    Mike
    #12
  13. johnnyc14

    johnnyc14 Been here awhile

    Joined:
    Mar 8, 2008
    Oddometer:
    205
    Location:
    St. Albert, Alberta
    Well, I've made some more progress. I got the front wheel cleaned up and mounted.

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    The brake pedal and center stand are now finished and mounted.

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    I used a "plastic nail" typed trim fastener and a rubber washer as a center stand stop and the old part was MIA.

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    The swing arm bushings and felt packing rings arrived at the Honda dealer and I got that stuff installed.

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    Up here in Alberta it's been a cold dry December, -20 C or colder all month. When it get like this and you work with your hands alot you get the dreaded and amazingly painful finger tip skin cracks. A great remedy to relieve the pain is to fill the crack with Crazy Glue. As soon as you apply the glue and it hardens the pain is gone! Here's one of the many I'm sporting right now after a week of working on the bike.

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    I got the speedo and tach sanded and repainted but the faces are quite faded. I keep seeing NOS ones on ebay but I can't see spending $350.00 for them.

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    My front fender has a big crack in it and I've been looking for a good one on ebay but good ones seem hard to find. There is a motorcycle wrecking yard near by and I'm going to take a trip out there to see what they have.

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    The pile of grungy parts is slowly being replaced with clean refinished ones, gotta like that!

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    #13
  14. MNellis

    MNellis Been here awhile

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    Nov 5, 2008
    Oddometer:
    127
    Location:
    Georgetown, TX
    Nice job on the front wheel. The spokes look great. What sort of condition were they in originally? Did you disassemble the front rim to clean the hub and spokes?

    Eventually I'd like to disassemble the front and rear wheel on my '68 CL 350 project. It currently looks like this [​IMG]


    Keep the details coming, it's a big help to me in my project. BTW, nice job on the brake pedal/shaft fix.
    #14
  15. Dabears

    Dabears --------------------

    Joined:
    Mar 10, 2007
    Oddometer:
    753
    Location:
    Atlanta
    Can you share the steps you followed to cleanup and polish the lower fork legs? They came out really nice, and since I have some to do myself I'd like to hear from someone who's already done it successfully. Thanks
    #15
  16. MNellis

    MNellis Been here awhile

    Joined:
    Nov 5, 2008
    Oddometer:
    127
    Location:
    Georgetown, TX
    Sorry to threadjack this great thread but here is one method that worked for me.

    http://1968hondacl350.blogspot.com/2008/11/cleaning-fork-legs.html

    #16
  17. Dabears

    Dabears --------------------

    Joined:
    Mar 10, 2007
    Oddometer:
    753
    Location:
    Atlanta
    Thanks- that looks like a great process for fork legs that are in much better shape to start then what I have- Mine have serious corrosion that will require a number of sanding steps. I may do the stipper thing first anyway to take any clear coat remants off. I've heard people using oven cleaner as well...
    #17
  18. johnnyc14

    johnnyc14 Been here awhile

    Joined:
    Mar 8, 2008
    Oddometer:
    205
    Location:
    St. Albert, Alberta
    MNellis, I used about the same method as you on the fork legs. Stripper then I used scotchbrite then polished on my buffing wheel. The spokes were pretty grungy and took a lot of time to clean, I used fine emery cloth that comes in a roll and just pulled a strip of it around each spoke 1 at a time and worked the strip back and forth to remove the corrosion. The hub is not as nice as I would like. I am thinking of ordering a new set of spokes, there's a guy on ebay who sells front and rear sets for about $100 including shipping.

    I refurbished my rectifier and voltage regulator, replaced some damaged wires and the heat shrink.

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    I drilled and tapped the swing arm pivot shaft and installed a standard grease fitting.

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    I bought new valves on ebay and reground the seats with a 3 angle valve job. I'm still waiting for a cam chain and some tensioner parts.

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    It's coming together slowly.
    #18
  19. johnnyc14

    johnnyc14 Been here awhile

    Joined:
    Mar 8, 2008
    Oddometer:
    205
    Location:
    St. Albert, Alberta
    I finished re-finishing the valve seats and did the final clean up on the head today. I also got all the other engine parts finish cleaned for re-assembly. I'm pretty sure I have all the part I need now. I have a Sioux valve seat finisher and all the stones and pilots that I got cheap at an auction many years ago. It is very handy to have.

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    I got new valve seals from my local Honda dealer, expensive little buggers!

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    New camshaft damper rings also.

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    I've started polishing the engine covers and it's going pretty well.

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    Hope to get the bottom end of the engine together tomorrow.
    It was a nice warm day here today, +1 C. Last Saturday this is what it was like here.

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    #19
  20. MNellis

    MNellis Been here awhile

    Joined:
    Nov 5, 2008
    Oddometer:
    127
    Location:
    Georgetown, TX
    Great looking pictures. You're correct, those valve grinding tools would be real handy to have. Do you have the diamond tool to clean and face the stones?

    The spokes on mine are very grungy as well and I'm not having much luck getting the look I want by cleaning them on the bike. I have not tried the emery paper though. I was afraid of sanding through the plating. I've seen the spokes on eBay and they would probably do the trick too. I called Buchanan the other day about some stainless steel spokes and was quoted about $105/set...ouch, but I bet they'd look great. My biggest shock was the quote for rechroming the fenders. They couldn't be exact without seeing the pieces but they estimated about $300+ for the rear. Re-chroming the wheels was not cheap either.

    If anyone has a recommendation for a Chrome shop, I'm all ears.
    #20