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motor_head
  • Rank:Silver Member
  • Posts:84
  • From:USA

Date Posted:12/24/2010 11:01 PMCopy HTML

Hey all, just joined the forum today. Been restoring CT70s for a while, but I picked up a running '81 185S for $150 and I am anxious to do a ground up restore on it. No rust in the tank, runs and shifts good, and doesn't leak or smoke. I feel like I got my moneys worth. Like a lot of others I've seen, it has been stripped of the lighting and instrumentation,but I've already found most of the original lighting and a speedo cluster on Ebay and in salvage yards. Wiring has been tampered with, but I'm hoping I can find help here when I need to reference the original wiring layout. Thanks for hearing me out.

jjpaul #1
  • Rank:XL Board Member
  • Posts:6
  • From:USA

Re:185S Resto Project

Date Posted:01/02/2011 11:01 PMCopy HTML

Great buy. I picked up a 1980 today for 300. Runs, leaky forks. You need to push the throttle away from you on this bike, it it like that on yours?
jjpaul #2
  • Rank:XL Board Member
  • Posts:6
  • From:USA

Re:185S Resto Project

Date Posted:01/02/2011 11:03 PMCopy HTML

Looking for tail lens and front and rear signal lights.
motor_head #3
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:185S Resto Project

Date Posted:01/03/2011 4:07 AMCopy HTML

Wow....I haven't heard of a throttle that works bass-ackwards!! Are you sure something isn't reversed? I think the '79 and up models are all the same in the throttle area. Congrats on your purchase.
jjpaul #4
  • Rank:XL Board Member
  • Posts:6
  • From:USA

Re:185S Resto Project

Date Posted:01/03/2011 10:32 AMCopy HTML

 Something's not right with it. It's real tight also and has tape around the cable and housing.
jjpaul #5
  • Rank:XL Board Member
  • Posts:6
  • From:USA

Re:185S Resto Project

Date Posted:01/03/2011 5:50 PMCopy HTML

 I think it has the wrong throttle tube it doesn't have a flange on it, ordered a new one, will see what happens.
Swiss #6
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:185S Resto Project

Date Posted:01/03/2011 6:47 PMCopy HTML

The bad throttle sounds like someone crossed the cables on a dual cable throttle.  One cable is pull to open the throttle and the other is pull to close the throttle.  Of course they work in opposite directions on the throttle tube.  If you used the closing cable to hook up to the carb opening side it would work in reverse like you are seeing.  This is assuming that your carb uses a rotary wheel to open and close the slide. 
It is harder to describe then to understand!  HA!HA!  A new throttle tube won't change anything unless you hook it up correctly, which you do not have at this time. Look in the shop manual or simply work the throttle in the normal direction and see that it pulls on the cable end at the carb.  Do you have 2 throttle cables or is your throttle housing set up to use 2 cables?

Swiss
jjpaul #7
  • Rank:XL Board Member
  • Posts:6
  • From:USA

Re:185S Resto Project

Date Posted:01/03/2011 7:17 PMCopy HTML

 Single cable. Took it apart and cleaned. Lots of grease and buildup on inside of the tube and on the bar. Seems to work correctly now when not on the handle bar, but when I put it on the bar and tightenn it's tight or won't move at all. I'm pretty sure at this point it may be the tube. Thanks for the replies.
motor_head #8
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:185S Resto Project

Date Posted:07/01/2011 4:26 AMCopy HTML

I just received all the black parts of this bike back from the powdercoater with a beautiful gloss black finish and I'm ready to prep and spray the tank, rear fender and side covers. I will post pictures soon. This bike is a beeyotch to find parts for!!

Does anyone have a good source for tank and side cover decals? This is a 1981 model. I haven't had a lot of luck so far. Thanks.

D.W.
MarcP1956 #9
  • Rank:Bronze Member
  • Posts:37
  • From:USA

Re:185S Resto Project

Date Posted:07/07/2011 5:56 AMCopy HTML

I have exactly the same bike and have quite a few spares. CDI ignition parts, wiring harness, spare engine (kick-starter gear needs repaired but runs very well and has about 2800 miles on it), and a bunch of others stuff purchased on ebay. My bike has yet to break down and sadly I am selling it so I will not need all the spares. I also have a factory service manual that might not go with the bike. (All depends on what I sell the bike for.) Let me know what you need and I may have it. The whole bike is $750 and runs well with all the lights, turn-signals and things working as they should http://oregoncoast.craigslist.org/mcy/2456211769.html . The best you can do for side covers is to continue looking on ebay, the decals - paint them on. I think I found some a few years ago when I was thinking full restoration, but can't think of it now. If I find the source I will past it on to you.

Shalom, Marc
MarcP1956 #10
  • Rank:Bronze Member
  • Posts:37
  • From:USA

Re:185S Resto Project

Date Posted:07/07/2011 5:35 PMCopy HTML

Here is my bike:

[IMG]http://i789.photobucket.com/albums/yy177/marcp1956/166.jpg[/IMG]

[IMG]http://i789.photobucket.com/albums/yy177/marcp1956/161.jpg[/IMG]

Shalom, Marc

brettzilla #11
  • Rank:Silver Member
  • Posts:94
  • From:Canada

Re:185S Resto Project

Date Posted:07/07/2011 6:59 PMCopy HTML

 here's a site for decals:

http://kz900.com/decals-hon.html

if you look for it, you'll find a decal for the XL500, and one for the XR185. it would be pricey but you could combine the two decals to make an XL185.
MarcP1956 #12
  • Rank:Bronze Member
  • Posts:37
  • From:USA

Re:185S Resto Project

Date Posted:07/09/2011 8:21 PMCopy HTML

Motor head, How is it going? Looking forward to seeing some more pics. Show us pics of your powder coated parts. This sounds like a great project.

Shalom, Marc
motor_head #13
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:185S Resto Project

Date Posted:08/10/2011 1:28 AMCopy HTML

Its been a while since I've been able to get back to restoring this bike....Afew more bikes found their way into my garage including a Victory V92 Cruiser, an '84 Honda VF700 Sabre, and a Suzuki TC185. Wife thinks I've gone kookoo. I have all the black parts powdercoated .........










Got all the shock parts polished up......New cushion assemblies...OUCH!!!$$$$




Assembled, minus the bushings.....







Frame and swingarm assembled................







New fender....I will match the paint for the rest of the bike off of this.........



New rims and spokes......................




Just a side note.....my right side cover was missing as they all seem to be....but I found this busted one in a salvage yard......





I built a new edge out of plastic epoxy and fiberglass cloth...........







And finally, after final shaping and plastic primer.......




The side cover still needs a little more tweaking before its ready for paint.

Thats all I've done to this point, but I'm gonna stay on it hard and heavy for a while.
HJR #14
  • Rank:Gold Member
  • Posts:104
  • From:USA

Re:185S Resto Project

Date Posted:08/11/2011 12:54 AMCopy HTML

That's some nice work! Keep us posted, can't wait to see the finished work!


ErnestT #15
  • Rank:Platinum Member
  • Posts:354
  • From:USA

Re:185S Resto Project

Date Posted:08/11/2011 11:46 PMCopy HTML

Lookin' good.
MarcP1956 #16
  • Rank:Bronze Member
  • Posts:37
  • From:USA

Re:185S Resto Project

Date Posted:08/17/2011 3:47 PMCopy HTML

You do good work. This is a great thread, I am looking forward to the next post.
motor_head #17
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:185S Resto Project

Date Posted:09/05/2011 4:21 AMCopy HTML

Got a little more accomplished on the XL185 this week. Restoring and cleaning up these sub-assemblies is painstaking and tedious. On top of the assemblies themselves, I re-zinc and polish all my hardware, which brings it to a crawl.

Got the fork sliders polished.........

Before....




After....



Rebuilt forks with new seals........................



Got 'em back on the bike, along with handlebars, new light switch and new Choke cable. I restored the fork lock to like new condition and re-installed it as well.........



Started restoring the speedometer. It's a pain in the ass to get the bezel uncrimped to get inside.....it took me an hour and 15 minutes with a small precision screwdriver and a tack hammer to slowly work the crimp up without doing any damage.........





Finally got it off, lubed the speedo gears, cleaned the backside of the lense and put it back together to prep for some satin black paint and a new maintenance decal.  Although I have zeroed my speedos in the past, I decided not to attempt this one since they are so hard to find in good shape. Tenths ring is a little yellowed, but I had to roll with it........







Rather than replace the horn, I cleaned it, masked the terminal block, and shot it with Duplicolor Instant Chrome. On a slightly textured surface, it has the appearance of fresh zinc............................



Next will be the headlight and taillight assemblies. I also have new lever and perches, and grips ordered to finish out the handlebars

 
brettzilla #18
  • Rank:Silver Member
  • Posts:94
  • From:Canada

Re:185S Resto Project

Date Posted:09/06/2011 3:45 AMCopy HTML

 thats all looking so good. i'm doing the same to my 1978 xl175. and frankly you're doing things i wouldn't have thought of and want to do on mine.

for instance, you powder coated your shock springs. will the coating not crack off after a few bumps?  they look great and i want to do mine too, but i've never heard of that and i wonder if it will really work?
motor_head #19
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:185S Resto Project

Date Posted:09/08/2011 3:31 PMCopy HTML

Brett, I was wondering the same thing about the shock springs going into the project, but my powdercoater is a pretty sharp guy. He has assured me that they can withstand the flex, and I have flexed them some with no problems. He has powdercoated a set on a bike he owns with no problems. I think although the entire spring flexes a fair amount, the vertical movement of each individual coil is not that much. At least I hope so, time will tell.


Her is a link to some more of my powdercoater's work....he's a magician!!!

http://www.kneeknockertruck.blogspot.com/

David W.
brettzilla #20
  • Rank:Silver Member
  • Posts:94
  • From:Canada

Re:185S Resto Project

Date Posted:09/08/2011 7:59 PMCopy HTML

this is really good news. my rear shocks were going to be the weak link in the chain on this bike, and now i think i can make them look as good as yours.

i also did some asking around. i'm told that powder coating makes the best bond on metal that you can get, better than paint, plastic, rubber or whatever. i'm going to get my guy to do them up. he'll polish the hardware for me as well, so it'll look pretty sharp.
motor_head #21
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:185S Resto Project

Date Posted:09/09/2011 2:59 AMCopy HTML

Be sure and post us some pics if you can!!
MarcP1956 #22
  • Rank:Bronze Member
  • Posts:37
  • From:USA

Re:185S Resto Project

Date Posted:09/09/2011 3:59 AMCopy HTML

Excellent work! Great thread.
motor_head #23
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:185S Resto Project

Date Posted:09/09/2011 3:23 PMCopy HTML

Thanks Marc,
Do you still have your 185? That looks like a pretty nice old bike, (and it even has the elusive right side cover!)
motor_head #24
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:185S Resto Project

Date Posted:09/10/2011 7:57 PMCopy HTML

A couple of hours more spent on the 185. Progress is really slow, but so far the outcome has been worth it.

Instrumentation mounted................





Horn mounted....................



New light/horn switch, grips, levers and perches.........................




I had to rebuild the Kill switch including plastic welding, sanding and refinishing, the hardest part was painting the tiny raised letters for the "Run" and "Off" positions.............



MarcP1956 #25
  • Rank:Bronze Member
  • Posts:37
  • From:USA

Re:185S Resto Project

Date Posted:09/13/2011 3:55 AMCopy HTML

No I don't. Something had to go, so the little Honda was it. It was that or my Triumph Bonneville, GL1000 Gold Wing, Norton Commando or my 2008 Yamaha XT250 (this was promised to my wife upon completion of a motorcycle course.) Hard choices - I really liked the little bike. Only if my shop was bigger and my pockets a little deeper. Did you repair the engine stop plastic knob? It looks like new. You are going to have one sweet little bike!
MarcP1956 #26
  • Rank:Bronze Member
  • Posts:37
  • From:USA

Re:185S Resto Project

Date Posted:09/13/2011 3:59 AMCopy HTML

Motor head, If you were closer I would love to come an see your bike. I do a bit of restoration work myself - love to fix those things that others would throw out and make them look like new.
motor_head #27
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:185S Resto Project

Date Posted:09/13/2011 4:01 PMCopy HTML

Marc, I get more enjoyment out of refurbishing rather than replacing whenever possible. I won't use anything I cant make look new, but I try every trick out there to make it right before I give up and hunt replacement parts. It all started with CT70s, and you can still find most of that bike NOS or in the tons of people who still buy and sell on Ebay. I have definitely found this bike to be a challenge to find some parts for. I'm going to an auction this weekend to bid on a Honda 305 Dream, I definitely don't know what I'll do for parts if I bring that one home...LOL
motor_head #28
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:185S Resto Project

Date Posted:09/16/2011 9:28 PMCopy HTML

Not much to report this week on this project. I did get the wheels laced and ready to be trued. SHEESH!! The back wasn't bad, but the front was a bear with the non-symmetrical hub setup. Took a WHILE to figure out the order of assembly with the spoke plate that bolts onto the right side of the hub. If you do it wrong, ya get to start all over....(ask me how I know)!! There are four different type spokes that compose the front wheel assembly, and a million ways to screw it up. A few Coors Lights and a few swear words later, I finally got it right.....




MarcP1956 #29
  • Rank:Bronze Member
  • Posts:37
  • From:USA

Re:185S Resto Project

Date Posted:10/23/2011 5:35 PMCopy HTML

More, more, more ... These threads often end, I would love to see this one to completion.
motor_head #30
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:185S Resto Project

Date Posted:10/25/2011 11:25 PMCopy HTML

Should be more to come soon Marc, I got a little bogged down with a couple of issues on it. I wasn't happy with the front wheel, the new spokes didn't catch enough threads on the nipples so I decided to rework it. I discovered (word to the wise) that the Thai made rims are slightly larger on the inside diameter, and their spokes are slightly (2mm) shorter than stock. Put those two together and ya got a problem. Finally ironed it out by ordering new spokes from Honda instead, they should be here tomorrow and hopefully I'll have a roller in a few days.



Go soothingly on the grease mud ... as there lies the skid demon! ...






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