1969 CL450K2 Cafe Project

[squeak003]

I call it my barn find.

I picked this up at the beginning of the month for $300. It's my second motorcycle, my first being an '85 honda shadow vt700c. I think I'm going to go cafe on this one. The last time it was registered was '98. The tires are dry rotted dunlop gold seal k70s that amazingly still hold air. Its missing a few things like passenger foot pegs, emblems, stock mufflers, the center stand, and maybe a few more things. I'm told the miles are original, but it makes me wonder as they are so low.

Right after I pulled it out of the jeep.








I pulled the gas tank and side covers. Found a few interesting things. The motor's number starts with CB450E-*******. I found the motor was swapped in from a cb450. I found later on it is from a CB450K7.

first came the side covers. found the bike used to be red.



this fell out when the right was pulled.



and what do we have under the right.



and the left.



under the seat.



in the tool box.



battery box.



bottom of tank.



under tank right side.



under left side. whats that hanging there?



uhhhh.....we have a leak.....



and more of the leak along with a a missing screw

[squeak003]

Then the fun started. I pulled the gas tank and side covers. Found a few interesting things. The motor's number starts with CB450E-*******.which means the motor is swapped in from a CB450 was swapped in. Later I found that its from a '74 CB450K7

First came the side covers. I found the bike used to be red.



This fell out when the right was pulled.



And what do we have under the right.



and the left.



under the seat.



in the tool box.



battery box.



bottom of tank.



under tank right side.



under left side. whats that hanging there?



uhhhh.....we have a leak.....



and more of the leak along with a a missing screw

[squeak003]

And more fun.

oil doesn't smell burnt



i love the hose foot peg covers.



it needs a bath









looks like that needs replaced



hmmmm where did they go???





nice crack....



and another crack



key number matches the cylinder number on the steering lock



missing the center stand



this appears to be bent on purpose

[squeak003]

oil doesn't smell burnt



i love the hose foot peg covers.



it needs a bath









looks like that needs replaced



hmmmm where did they go???





nice crack....



and another crack



key number matches the cylinder number on the steering lock



missing the center stand



this appears to be bent on purpose



here are the pictures from a long night, 5 hours, of sand blasting. i'm hoped to finish getting at least the bondo off the next night. i didn't at the time know what i was going to do about the jb weld looking stuff.

under side had 5 coats of primer/paint/primer/paint etc. took forever to get clean


dent in left side


dent in right side


jb weld looking crap


im curious on how this happened (a little left over bondo i have to remove that is 1/2" thick)




left side




right side

[squeak003]

Bondo and jb weld gone!!! No Holes!!! Used a 3M stripping wheel.







Looks like I'll be doing something to the interior too. Maybe electrolysis? I don't know yet.

[squeak003]

I think that when I'm told "It's not running right now. I think its because someone was messing with the points", I'm going to pull the points cover and inspect.

There was one bolt holding the points cover on


I pop the cover and this happens


Out falls the points plate and the other screw to the cover. Its also missing the screws that hold the plate in place. I'll have to source them from somewhere. I also noticed that the bolt and washer in the center there are jb welded in place. What the heck is with this guy and jb weld.

Then I look at the points and find this


Now I know why I'm not getting spark. The tab was bet over and wouldn't allow the points to separate. It wouldn't allow the cam to even move the points.

[squeak003]

Woke up to a beautiful day. My fiancée said I needed to do some work around the house, of which I agreed. I went outside and pulled the bike out and put it in the driveway. I strategically placed it in front of the lawn mower so I have to handle it once a week which will keep me motivated. I mowed the grass then decided I needed to be able to sit down for a few minutes while doing something. I broke out the bondo and mixed up a small amount and got to work on the tank. While the first layer was drying I decided to get the 5 year old out and have him help me tear it down some. I got this far before the down pour started and quickly put a damper on my plans for the day.

Petcock was pulled before I started the bondo work. Its clogged.



got it this far (removed rear fender, seat, rear lights, battery box, and exhaust all for clean up)

[squeak003]

Now for an update.

These arrived in the mail:


These also came. I forgot to do a before shot. These were all covered in rust. The stand needs a rod welded on to assist in lowering the stand as it is broken off.


Pulled the rust covered battery box and blasted it.




I then did a lot of bondo work. Its getting there.











Next comes the seat. The cover was torn and held together with wide black tape.











Then to the blaster it went









My next step for the seat is cutting off all of the left over metal on the side where the rust was removed to smooth the edge out.

[squeak003]

Here it is with the cancer trimmed.

[squeak003]

Michigan's no title process is sooooo easy. I walked in with a bill of sale. They ran the vin, which took an hour. It came back clear. I paid $15 title fee + $15 taxes from original purchase and I was out the door with a new title on the way in the mail.

I got my factory service manual in a couple days ago. It's binding was toast. I took it to Staples and in an hour it has a new spiral binding. I turned out better than I had hoped.



Here is my mock up so far.







And the rear is left open and will be the shape of the stock tail light. I will Glass in a bracket to mount it too.



My original lens is cracked so I will have to find a new one and this is just cardboard but you get the idea.





I really can't wait to get my clubmans....

[squeak003]

What a day this was. Next will be boiling the carbs in lemon juice and a good rebuild. After that I'm in the air about adding another coat of bondo to the top of the tank or starting the paint removal on the frame.

Here is what has happened in the first few hours of the day.

Its going to be a long night at the sand blaster for all of the metal. Everything else will get brushed with dishsoap and water.



Your standard H4 Halogen swapped in with some silicone for a sealer. The joy of hillbilly work.



I also have 2 random unhooked plug ends with no loose wires in there.....hmmmmm



My working conditions.....man I can't wait to hear back on the new house with the 4 car garage.



Medusa tamed



Its getting there





Man is it dirty





And man do I need new tires....



I Would assume this is the source of my oil leak. Its missing 4 bolts.



Found a broken fin and did what we do on aircraft. File it down and round the edges.



Goober welded gear shifter that is nice and FUBAR.





ENGINE OUT!!!!!! and a picture of my ugly mug.





Gel degreaser on!







No more kickstand......for now I will use bricks untill its cleaned and painted....then the stand will go back on



Another layer of bondo.





And last but not least. I need a new chain. Its not supposed to bend that way and it has 4 master links in it.

[squeak003]

Next day was 45*F and rainy. Therefore I could not work on the bike outside. So I got out the lemon juice. Made my house smell like ass. It boiled over on me twice. What a mess. Carbs are nice and clean. I put them back together with a new rebuild kit. I have to check float level but other than that they are ready to go back on and be synced.

[squeak003]

Then it warmed back up. For a day.

Got the cover off. Cool. It took an impact screw driver to get the top 2 screws out.



I'll found that the little ball bearing in there is the one that everyone says not to lose.



Did a little sand blasting the night before also.



And just the underside of the rear fender



And then I decide to open up the valve covers.....CRAP CRAP CRAP CRAP CRAP!!!!!!!!
exhaust side :(




Intake side :)



And a little bit of cam chain rub on the intake cover



Now I have to pull the head to figure out what the heck is going on.

[squeak003]

So because I'm in a stand still with the motor, I did some sanding on the tank.







And as its not winter here, well technically, I decided to put the kid's sled to use in engine movement.

[Troutrider]

Hmmm, how many days has it been since you got it home? You obviously need some teenagers running around to sap your energy and keep you from working on it. The 450 is a sickness in itself. I bought my first one to cafe'. Found out the engine was thrown together from several p.o.s. worn out motors. Bought another one and started on it so I'd have 2 of everything. Started working a lot of overtime and I now have one on the lift, one beside it, and another motor covering my table. I walk past all of it on the way to the beer fridge. Occasionally I stop and look it all over.
Any old way it looks like you're coming along nicely. I've seen a lot worse examples come back from the dead. I'm sure you've been over to www.hondatwins.net and looked around. Lots of info and knowledge there along with some very helpful souls who don't mind answering questions. Unless you are intimate with torsion valve trains you will be needing them at some point. Carry on my friend. I'm counting on you for inspiration.

Troutrider