Honda CJ 360 Custom Cafe Racer build progress

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Honda CJ 360 Custom Cafe Racer build progress

Post  Tim on Tue 5 May - 12:33

Hi guys,

This will be my first project and all hints and tips would be welcome.

I'm also using this topic as a material bill.

And I'll try to make as many pictures in the process as I can.

The Bike is a CJ 360. Its the same as a CB 360 but without an electrical starter and a 5 speed transmission instead of 6. A simpler paint job and another exhaust suspension. The CB was a luxe edition as the CJ was the lighter racer.

Here I'll make an attempt to restore it as a cafe/bratstyle racer.



It was on sale at kapaza for 300 described as a cj 360 with missing parts. I bid 150 as I thought it was in non running condition. The next day I got mail from the guy saying I can come pick it up. WHOEHOE.

So I went to the guy and guess what, as you can see on the picture its missing carbs, exhaust, etc.. but he still had all the stuff in a box! And to top it off he told me the engine was in mint condition. The guy who he bought it off came to deliver the bike driving it. He bought the bike to restore a CB 360 (which he did) but only used the battery, some rubber grommets, mufflers and a some small parts. He showed me the agreement and he payed 750 for it 2 years ago. I felt like I was ripping him off.

So the things that need to be done the get it on the road:

Overhaul front forks
Change tires
Renew chain
Renew spokes
New battery
New mufflers
New rear shocks
New oil/gas/brake lines
Redo wiring

Things to do to make it cool:

Lowering
Megatons
customize seat
customize tank
clubman bars
Drill brake disk
and tons more

The build isn't gonna go fast as I'm not spending more then 250 a month on it.

Total cost until now:

Donor bike Honda CJ 360 150
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  marc on Tue 5 May - 12:43

Nice base for a cafe Laughing Laughing

Keep us updated!!!

Are you going to restore the engine?
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Tim on Tue 5 May - 13:18

No, I was going to until the previous owner gave me the workshop manual where it was dated that it has been reworked less then 3 years ago and it only has a total of 38.000km on the counter. I'm gonna get a battery and hook the engine on the rest of the electronics to try and start it. Then I'll listen to it and see if it needs work.



I'm thinking of sanding and repainting it but first I wonna get here to run.

BTW anybody sanded an engine before in its whole? I was thinking just to cover up all the holes and not to aim at the gaskets. If I don't have to I don't want to take it apart.
I was also planning on replacing the bolts withe rvs ones but then I read something about aluminum and rvs not going well together.
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  marc on Tue 5 May - 14:23

Yeah 38000 seems nothing, mine was wrecked with a mileage of 39000 so... Razz

These types are known to have a problem with the oilsupplie in the head for the camshaft, often the camshaft won't get enouf oil! With the rest of the damage!

A few tips:
Take of the valvecover and check the camshaft and rockers!! Also take off the clutchcover and check the oilfilter, pump and rotor! If its full of crap the camshaft won't get any oil!! Thats my advise Very Happy Not that much work!

don't sand the engine while its assembled! The sand will gett in places where you don't want it!!

Alloy and Stainless steel isn't a good combination! You can buy new bolts a CMSNL.com! Are look for replacements!

Good luck Cool
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Tim on Tue 5 May - 14:57

I saw you painting your engine, how did you clean it well enough so paint will stick to it?

I'm cleaning my engine with a steamer and some degreaser as we speak. But it looks like no matter what grease and dirt crawls into the pores (porin) of the aluminum. And I don't think its a good idea to paint over this as the paint eventually will fall off.

This is the engine color scheme I'm aiming for
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  marc on Tue 5 May - 15:46

I cleaned the loose parts with enginesoap and highpressure water! Worked perfect

Tip, don't use Motip, I used it, but when the carb leaked some gas the paint came of Sad

Question, do you have a spare set of insulators? The rubber intakes? Mine are ripped!!
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Tim on Tue 5 May - 16:43

No I don't have extra intake insulators, mine are cracked as well. But I don't think there cracked all the way threw. I was thinking of sealing the cracks with Tech7.
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Tim on Tue 5 May - 16:48

I layed out all the parts I have for the bike






I do have an extra exausth pipe ring holder as you can see in the last picture, but for all the rest I'm gonna wait until a bit further into the build. I don't want to give away parts as long as I don't know I'm going to need it.
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Tim on Tue 5 May - 17:46

Cleaning the engine with steam and a wire brush. I'm gonna get some heavy duty engine cleaner to get rid off the grime and crud in smaller corners and the bottom.

Before


During


After


Don't laugh but this is my garage.
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  andreas on Tue 5 May - 19:44

Hi Tim - be sure no one laugh!! Space is in the smallest hut!! A lot of "screwers" wish to have a "Box" like this. Nice project, cause this is one of the unpopular Hondas. So give all - to let her shine ! Andreas
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  650zed on Wed 6 May - 8:06

Tim wrote:Don't laugh but this is my garage.
Your garage is maybe bigger than mine...
I'm sure you can make some really cool place out of it!

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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Hofman on Wed 6 May - 22:59

cool thing you use for for cleaning the engine.
Is it some sort of hand steam cleaner?

Good luck with the rest
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Tim on Thu 7 May - 19:21

Hofman wrote:cool thing you use for for cleaning the engine.
Is it some sort of hand steam cleaner?

Good luck with the rest

Yeah,

Its a "karcher" hand steamer which my wive uses to clean the bathroom Very Happy

Its surprisingly strong for being this small. The output is like 3 bar.

I also bought some engine cleaner today. I'll try it along with the steamer this evening to get all the grease off.
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Tim on Thu 7 May - 22:38

Ok, so I just spended 3 hours cleaning the engine and its still full of snot.

I'll do it better next time when its out of the frame. But for now its nicer to work on.

The cleaner I bought.


Before


After



Question,

I think its ok, but is it normal that the "clutch lifter rod" can pull out without any force?



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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Gss on Fri 8 May - 0:18

Yeah thats normal, on suzuki's anyway. Maby Honda uses other techniques, but dont think so.
Its Just a rod that pushes on the clutch so the plates come off eachother.
But dont pull the rod completly out caus then the spring in the ''oilcap?'' (english for bourage,keerring? ) can get lost.

Sorry for the bad english.
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  marc on Fri 8 May - 0:58

Yes he is right, you can pull it out!!

But the way its in right now is wrong. The other side of the pushrod is round, the round sight needs to point towards the engine cover(side wich the photo is taken from).

Look at this picture:
http://www.cmsnl.com/honda-cb360-us_model1007/partslist/E++07.html

You cleaned it nice!! It was very dirty, no leaking seal?
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Tim on Fri 8 May - 19:43

No there's no leaking seals just 35 years of crap!

And f*ck ... its in wrong, but I can't pull it out or there's a spring that will get lost!!! Dilemma Dilemma...

So I'll try to turn it around tomorrow and if the spring turns ... I'll bet you'll hear me curse all the way to Australia!!!

I'm also going to make an attempt at wiring the engine so I can start it. If it runs I can start modifying the frame.
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Gss on Fri 8 May - 20:14

Well, you wont lose the spring if you do it gently. Wink
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Wallace on Sat 9 May - 1:26

A nice project. Good luck.
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Tim on Sat 9 May - 15:46

marc wrote:Yes he is right, you can pull it out!!

But the way its in right now is wrong. The other side of the pushrod is round, the round sight needs to point towards the engine cover(side wich the photo is taken from).

Look at this picture:
http://www.cmsnl.com/honda-cb360-us_model1007/partslist/E++07.html

You cleaned it nice!! It was very dirty, no leaking seal?

Okay, I pulled it out only to discover it was in the right way to begin with. Good news, the spring is ok.

Marc I'll check yours if I where you. There's a ball pointed end and a dimpled end. The dimpled end should be at the clutch lever side because there's a ball that fits right into the dimple. Look at the drawing closely.


Here's a link for an online manual for all Honda 260's and 360's I found.



After installing the cable boom, battery and carbs, I saw I don't have the fuel line's.

I checked at cmsnl.nl and the assembly is like 250!!!
I don't now how they calculate there prices, but I'll get some fuel hose someplace else.

Does anybody knows what the inside and outside diameters should be? Cause I can't find anything back in the service manual. I think ID should be 4mm but I don't have a clew what th OD should be.

So there goes my plan to start her today. Evil or Very Mad
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  marc on Sun 10 May - 0:42

Hmm tim you're right!!

Going to take a look at it tomorrow!!
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Tim on Tue 19 May - 16:28

So I've cleaned my carbs today.



I did a whole "how to" in the tech section. Read about it here -> Carb Lemon Soup
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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  650zed on Tue 19 May - 16:34

Tim wrote:I did a whole "how to" in the tech section. Read about it here -> Carb Lemon Soup
Nice one!

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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  Luckyboy on Wed 20 May - 3:17

Hi Tim, That will be a fun project to learn with...
and end result will be great to own, as it is all your own work...

I got the idea of small steam cleaner from you, well done.

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Re: Honda CJ 360 Custom Cafe Racer build progress

Post  650zed on Wed 20 May - 10:39

Luckyboy wrote:I got the idea of small steam cleaner from you, well done.
Yep, me too, that sounds good.
Now I just need to check where to find this kind of steam cleaner... scratch

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