77 CBGL project

[Siphor]

What seat is that?

[mogold]

What seat is that?

http://www.ebay.com/itm/1976-1979-Honda ... 1209wt_952

The price has gone down since I purchased it. The foam is very firm...too firm...the overall quality is pretty good though. It ended up costing me alot for the upholsterer to put it on...the pan I put it on was an aftermarket fiberglass and it was a little different than the factory pan..there wasn't enough material to use rivets...and their was some slack in the material at the bumpback so the upholsterer had to remove some stitches and cut some material so there weren't any wrinkles.

[mogold]

Also I am thinking about if I should be changing out brake lines and cables or if I will just be able to hide the slack? I am changing my brake lines anyways, tires and going thru the brakes this week.

I bolted up the clubmans...with only the brake control on the bar..will definitely have to shorten the brake lines...and probably the throttle cables...I forgot my camera...sorry....I'll take pics on sunday and post with details on the situation with the temporary workarounds.... I'll use them as is for sunday until I get it running etc..

[Fred Camper]

I bolted up the clubmans...with only the brake control on the bar..will definitely have to shorten the brake lines...and probably the throttle cables...I forgot my camera...sorry....I'll take pics on sunday and post with details on the situation with the temporary workarounds.... I'll use them as is for sunday until I get it running etc..

Fully agree, two throttle cables and one clutch cable must be shortened to ensure long term low effort. And I too replaced the front brake hoses as the extra cannot be reasonably tucked in.

[mogold]

Ok....a NOT so fun day on the project. Several issues came up.

-When putting radiator fluid in...it poured out of the thermostat housing. After an hour of waiting then getting frustrated pulled the radiator out to find that the thermostat housing bolts were loose! ....relieved and frustrated at the same time!

I spent several hours chasing "loose ends"..loctite existing bolts, replace missing bolts and nuts etc.

Clubmans....need I say more? ..Ok I will.......there is a magical balance between the front brake banjo and the guages...then the clearance issue between the bars and the side covers...... No such thing. I adjusted the bars up as far as I could for the brake banjo..then had to find a workaround for the stops. The workaround is temporary ...but I used epoxy tape to put nuts on the stops as seen in the pictures...still not sure how I'm going to make it permanent. I at least now know what clearance I need. The brake lines are at least 6 inches too long........throttles can work but will need shortened too.

I spent several hours fishing the wires through the clubmans (Make the holes bigger than you think they need to be)...kindof expected..but then again.....alot more effort than anticipated.

Flub of the day was when I realized that I had wired the left hand controls before putting the clutch lever mount hardware on....."crap..(cry) there went 4 hours"


anwyay..kindof productive...very frustrating day...I now understand why more people aren't putting clubmans on.

[mogold]

continued

[Dangeruss]

Looking good!

[mogold]

Looking good!

thank you

[Fred Camper]

Looking very sharp. Most all who run Clubmans need steering stops added.

[mogold]

Looking very sharp. Most all who run Clubmans need steering stops added.

Yeah...unfortunately..I don't see a way around it. I thought of a good way to install adjustable stops....AFTER I put the front end on...of course <sigh>

[mogold]

Slowly but surely...spent half the day yesterday rewiring the clubmans and fixing loose ends. I'm having issues with the throttle cables binding...still trying to get my brain around it...they were fine until I hooked everything up. Tried to reroute them...still no luck.......go figure.

She's getting pretty dirty and badly needs a bath....between the greasy handprints and the yellow pollen ..its hard for me to tell what it really looks like. I ordered the elbows for the exhaust..still waiting.

If everything goes ok I think I'll try to get it started tonight...need to build a couple of wire jumpers for the universal starter. Wish me luck

[drcroog]

Try running the throttle cables between the forks
Your bars are lower than mine but it should still work
The result is a nicer run for the cables and in my case the throttle works better than with the stock bars (and the length is fine)

[mogold]

Try running the throttle cables between the forks
Your bars are lower than mine but it should still work
The result is a nicer run for the cables and in my case the throttle works better than with the stock bars (and the length is fine)

Thanks for the tip...I'll take a look this evening

[mogold]

Got the bike started tonight....wahoo! Seems to run pretty good. I fried a brand new generic starter relay in the first 1 second push of the starter...frustrating. A few wiring issues I need to chase down...blinkers stay solid when turned on and no horn. Tach was stuck at about 1500 rpms....Still need to fiddle with the throttle cables and the neutral wire connection. Will try to finish the exhaust up soon.........I'm tired and going to bed

[WhatThaFrig]

Try running the throttle cables between the forks
Your bars are lower than mine but it should still work
The result is a nicer run for the cables and in my case the throttle works better than with the stock bars (and the length is fine)

That's what I did with my throttle cables, too.