1977 Honda CJ360 - Café SOS

Discussion in 'Projects' started by Sonreir, May 6, 2011.


  1. Hey all,

    I've been on this project since October 2010, but I figured I could still get a post up. This is my first bike and also my first build. I don't have a lot of words to put in just yet, but hopefully the photos I've taken so far will tell a good story...

    The starting point:
    [​IMG]

    Starting the tear down:
    [​IMG]

    After the first three hours:
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    [​IMG]

    Starting the grinds and chops:
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    Top end noise cause found:
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    Motor disassembled:
    [​IMG]

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    All chopped and ready to go:
    [​IMG]

    Close up of rocker arm damage:
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    Alternator cover start:
    [​IMG]

    After sanding with 220, 400, 600, 800, and then 1200 grit paper (by hand):
    [​IMG]

    And buffed!
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    Points cover polished and clear-coated and alternator cover primed:
    [​IMG]

    Paint onto the valve covers, breather cover, and alternator cover:
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    Alternator cover done along with more coats to the valve covers and breather cover. One foot peg painted, too:
    [​IMG]

    The very first piece to go into the "done" pile:
    [​IMG]

    Old gauge face:
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    New gauge face:
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    With white LED bulb replacement:
    [​IMG]

    Tank stripped and metal welded in for flap mitigation:
    [​IMG]

    Start of the knee dents:
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    First layer of bondo:
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    Springs, just off the bike:
    [​IMG]

    Fork lowers primed:
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    And then painted:
    [​IMG]

    Carbs disassembled and cleaned:
    [​IMG]

    Float bowls look better:
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    Reassembled and diaphragm covers painted (I've since redone them in a brass color, but no pics yet). Also replaced the screws with caphead style:
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    Rear springs after a two week soak in muriatic acid (no more chrome or rust!):
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    Frame painted:
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    Swingarm painted:
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    New parts arrived:
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    Electronic transistor assist under construction (I've since abandonded this. Turns out it works with a dizzy):
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    New VIN Tag:
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    Springs coated in PlastiDip:
    [​IMG]

    Control levels stripped of rubber and glue and then polished:
    [​IMG]

    Cleaned up the coil mounts and polished up a heat sink for a different project:
    [​IMG]

    Some of the rear shock parts painted up:
    [​IMG]

    Tank has the first coat of primer (Mainly to identify further flaws that need to be sanded. I'm not going for color anytime soon):
    [​IMG]

    Front wheel before disassembly:
    [​IMG]

    Half of the front spokes cleaned up next to the half that still need it:
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    Old cam reground for an extra 30° of duration and .040" of lift:
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    New custom made forged pistons. 11g lighter than stock despite the extra 2mm of diameter and doming (compression from 9.3:1 to 10:1):
    [​IMG]

    Inside of the (rear) wheel before:
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    Inside of the wheel after wire brushing:
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    And after further rust treatment:
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    And some heavy-duty anti-rust primer to keep the oxidation at bay:
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    Brake hub cleaned up and given a shine. Not properly polished though, still a lot of scratches:
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    Front wheel cleaned up and laced up:
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    More toys in the mail:
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    Rear wheel before:
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    Rear wheel after:
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    New aluminum valve springs:
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    Goodbye stock airboxes and filters, hello velocity stacks (tuned for 3rd wave at 11,250 RPM):
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    Test fit for the stacks:
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    Rocker cover painted and baked:
    [​IMG]

    Front forks and steering installed:
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    A rolling frame (FINALLY!):
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    Started fabrication of a small brass dash to hold the speedo (I'm ditching the tach):
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    Plate to hold all the new electronics. The cylinder you see is a 15KuF capacitor which will replace the battery:
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    Speedo mounted up:
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    Engine cases cleaned, painted, and baked. Engine assembly will start this weekend:
    [​IMG]
     
    pjd likes this.
  2. Wow! You are an artist AND a craftsman!
    Thanks for the great pics!:mfclap:
     
  3. Nice :mrgreen:
     
  4. Thats bad ass. making me wish i had a bike project in my garage right now.
     
  5. DAMN. Nice work.. Beautiful project.
     
  6. Kewl beans..going to be an awesome runarounder when it is done...hurry up so we can drool.
     
  7. Beautiful so far. Keep up the good work.
     
  8. Engine assembly has begun!

    The valves, valve springs, new retainers, and new valve stem seals are all back in the head. The transmission is installed and ready to go in the upper crank case and the lower crank case has the kickstart assembly ready to go.

    The valve springs are aftermarket versions coming from R/D Valve Springs in Cali. The new retainers and clips are all aluminum to further cut down on weight. I'm not sure if the springs themselves are aluminum (I don't think they are), but they weigh in a 9g less than stock. They're good for lift up to .450" which is a lot more than the .381" I'm running.

    [​IMG]

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  9. Great work, can't wait to see the finished product!
     
  10. mjn

    mjn Forum Admin
    Staff Member

    17,284
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    Holy smoke man! Fantastic work! Looking forward to seeing it all done!
     
  11. Avboden

    14,511
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    I Ride:
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    Very nice!!
     
  12. Right on man Looks great!:mfclap:
     
  13. Update with no pictures...

    Bottom end assembled last night. Three times. The first time I hadn't properly aligned one of the bearings on the main transmission shaft and so everything had to come off. The second time, I'd just finished putting the clutch together and putting it on along with the oil filter and noticed a gear sitting off to the side. Turned out it had slipped off the transmission main shaft, somehow.

    On the plus side, the third time went smoothly and the bottom end internals are all set. I put on the clutch, shift lever, oil filter, and oil pump. I still need to do the oil pickup though. The head bolts are in place as well and tonight or tomorrow will likely see the pistons and cylinder jug go on along with the head. I've got some modeling clay I'm going to use to test the valve-to-piston clearance and I'll take a look at the clearances on the valve springs and retainers as well.

    One thing that was a bit funny, but I suppose one wouldn't notice it during normal operation... It's very difficult to shift into 1st and 5th gear unless I turn the crank at the same time. Cause for concern?
     
  14. you tried just dry shifting after assembly? i would think oil would make a bit of difference as to how it shifts

    btw, those piles of motorcycle parts everywhere look daunting! but now that i think about it, i have a valkyrie completely disassembled at the moment and there are bolts and clips and parts everywhere too...awesome build, cant wait for more pics and finished project
     
  15. One of the other 360 owners I know said not to worry about the shifting. His does exactly the same thing. Something about how the drum was designed....
     
  16. Lookin good... Just be careful with the capacitor. If it's too high a voltage it will blow all your bulbs, if it's too low a voltage it will blow itself up. Ask me how I know...
     
  17. It's 15,000uF rated at 14V. Given the antiquated charging system, I'm hoping this is sufficient. The tail and turns are getting swapped out for LED as well.
     
  18. If they are LED signals they should be fine, but if the are just LED bulbs in stock housings it may not cut it. Some replacement LED bulbs are rated at 12V, but cannot handle surges of anything over that. 14V should be fine for the cap, but don't be surprised if your LED's don't last too long.
     
  19. Thanks, Mitch. I'll let you guys know how it it turns out so, if nothing else, at least someone besides me can learn from it.
     
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