Manky Monkey Motors

Just bought this :D :D :D :D :D

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=200437496284&ssPageName=STRK:MEWNX:IT

Very nice people are going to deliver it as well!!!!

Can you all say.........................................................................Cafe racer!!!!!!!

Clive

nice project clive.fit snug next to the chop  ;D

Yeah, but what for?.......................and why?  Morrag

Bargain! be twice that here ::)

Oh yes!  with a shiny metal tank and a flat seat with a little hump behind.....  - bootiful!



For fun of course!  And because he can!

It's here!!!! :D :D

Already got a list of bits required, found most of them on good old fleabay, but am in dire need of a complete front brake caliper setup. If anyone knows of one knocking about, or has one sat in the depths of their garage, I'd be dead grateful for any help finding one!!! (The bikes a 1977 CJ250T, the same, as far as I'm aware as a CB250T)

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day114Feb1.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day114Feb2.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day114Feb3.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day114Feb.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day114Feb4.jpg)

cool  8) 8) 8)

nice little project that is clive.welldone mate

Here's another CJ for you to check out Clive.
Belongs to PD's kid brother Ryan. He's putting together a farm hack under PD's guidance at Loony's workshop. Half term holidays this week so he & his brothers are back to do a bit more.

.

I had one of them years ago.

 ;D
My first bike was a Honda CB200. Very similar engine & a wonderful little bike.

Snap.
Here is my mine at RAF Brawdy in 78. First big bike after a slowped Honda SS50.

Same colour as mine. Cool!

So why aren`t these pics in the old photos section?

Never thought to do it. Will have a look now.

my first was a cb 250.

Great pics, all of them!!!

Now.....has anyone got a front brake caliper for one?????? :D

Clive

If your are desperate, will a Superdream one fit?

I'm no expert, but I don't think so! (Waiting to be corrected by greater minds!! :D)

Thanks for the offer though buddy!

Clive

After a bit more research, I reckon I can straight swap some 250 Superdream forks into it, so PM sent buddy!

Anyway, yesterdays progress:

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day3.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day33.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day32.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day31.jpg)

Clive

The forks actually look identical to the Superdream ones so I wouldn't mind betting the Superdream caliper would fit.

don't think it will, as the mounting points are different! Not a drama now, as I've got a set of Superdream forks on their way, so now just looking for the caliper etc.

Todays progress:

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day4-1.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day41.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day42.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day46.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day45.jpg)

Next big job, while waiting for the forks to arrive is.......................... my favourite, wiring! Can't wait to get stuck into this! :D :D

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day43.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day44.jpg)

Doesn't look like too much progress, but I had to hand cut the new gaskets for the engine, and I'm also doing a paint job on a Harley tank and mudguards!!

Might be looking in the near future for a kindly monkey willing to make me up a mounting plate for the new speedo, warning lights and ignition!! :D :D Nothing too difficult, but probably above my skills, to make it look half decent!!

Clive

Update:

Nothing done, as I've been in Northern Ireland from Thursday until tonight!! :D

Clive

A business trip with her Maj's men?

No buddy, long weekend at the future 'out-laws'!!! :D

Clive

looking good mate  8) 8) 8) I always regretted passing on a couple of CB 360's a few years ago, would bloody love em now  ::) ::) ::)

Theres some idiot lights on flea bay off a yam virago 535 item number 120531152974

Going with the original set up for this now, but thanks for thinking of me buddy! ;D

Does anyone have a diagram of (or know about) the front wheel set up for a 250 superdream (CB 250 N) as the fork ends are slightly different to the CJ's, in that the CJ's have a clamp for the axle on the bottom of both legs, and the Superdream one has a clamp on one, and a hole for the bolt to go through on the other one. What I am unsure of is, does the superdream axle have a spacer on the disc side?

Clive

Looking at Mr Haynes diagram of 250 front wheel and spindle etc, the answer appears to be no.

I'll see if I can scan the pic for you but don't hold your breath!

Nope, can't get the scanner to work! - (I had an old one that was a bit cranky, but then so am I and we got along ok - then my daughter insisted I should have hers as she didn't need it any more, now I can't scan anything and she's gone to France!)

Try this.........Morrag

Mate, You're a star!!!!!!! :D

Looks like I must have a left hand drive bike, cos the CJ's Speedo is on the other side!!!  ;D
Sure I'll work something out, thanks again buddy!!

Clive

Your welcome, but check out the CX 500 forks and brakes, which are very similar, if not identical...Morrag

Free feel to all call me a knob for this, but I took the Superdream caliper apart to refurbish it.............and now can't work out/remember which way it mounts back onto it's mounting bracket?? ::) No excuse for it, I even have my camera pretty much on me all the time too!!!!

Any chance of a pic of the front brake caliper breakdown from the book buddy?

Also finished the front wheel, started the paint on the front forks (the superdream ones), the side panels, and found a seat unit for it!!

Should be some pics of some paintwork for it tomorrow!!

Clive

ok ya KNOB! ;D bolt the mount to the leg and the thickest part of the caliper bleed nipple side is on the outside of the disc
ps i know where ya live now saw the volvo in the drive  ;D

D'you mean you've been down this way? If so, you should've popped in for a brew and a nosey buddy!!!

I've got it sorted now, found a diagram on the net......but you're right I AM a knob!!

Clive

I say,I say, that's not very complimentary chaps!!, but as long as your sorted! I have the man. for Super Dream and CX here if you need any further pics. Morrag

Cheers matey! The only bits from a superdream are going to be the forks and caliper, so should be okay *insert a 'fingers-crossed' smilie here*

Clive

As promised, some pics!! :D

Side Panels

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day143.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day144.jpg)

This is with the first layer of clear only! First live attempt at goldleafing too! and hopefully, you can also see the 'ghosted in' chequers. Can only see them in certain lights, and look sooooooo good even if I say so myself!!

Forks too (there's chequers in the ivory on those too, just can't pick them out

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day146.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day147.jpg)

And the bike so far!

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day142.jpg)

Think this will be the bike for Basingstoke, rather than the chop, and hopefully it's inaugural trip will be the monkey nuts run! Fingers crossed!!

Clive

A bit more today!

Rear wheels off, and ready for paint. Shocks are painted, and back on. Rear of the airboxes are painted.

And have all these spares!!!! :D

Clive

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day14A.jpg)

Fantastic paint, as always Clive. I love the cream panels on the forklegs & the chequers.

Thanks buddy!  ;D Wasn't sure about the paint combination before I started, but now think it really goes!

Clive

Got some done today, as I was home from work!

Thanks to Mr Morrag, I could get the front wheel back on! It needs a little bit more fettling to be sorted, but is back on for now.

Rear springs didn't look right re-painted, so I'd stripped all the paint off, took them apart, and then used plastic dip to re-coat the springs, and put them back together, which then meant the rear wheel could go back on, which in turn meant the engine could go back in, and then the battery tray and airboxes.

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day193.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day192.jpg)

I then just laid the tank on for a look-see at how it's gonna be. The tanks only in it's first layer of primer at the moment!

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day191.jpg)

Clive

You're a fast worker Clive. Very smart.

Had a day of (almost) going backwards today!  :(  ???  :(

Firstly, went into the garage to find the primer had reacted badly on the tank, soooooo the whole lot had to come off!! Thank you to the god of Nitromors......again!! Decided to strip the front mudguard too!

Then wet sanded, and polished the side panels, and just as I was finishing the mop caught the edge of one and flung it across the patio! Serves me right for deciding to do the polishing in the sunshine, rather than over the purpose built padded floor!!! :D

On the up side, I also polished the first mudguard for the HD I've been working on!

And sorted the issue I had with the front wheel! Turns out one of the forks had an imperceptable bend in it, but was enough to move the fork bottom too close to the brake disc!

Clive

Completely re-built the wiring loom today! I love doing this, it's probably my favourite part of a re-build, just something satifying about creating one, from that jumble that is a wiring diagram! :D

Got some filler on the tank too!

A quick question though. I've got some different bars on their way to me, but need to drill some holes in them! Any tips on trying to drill holes in a curved stainless steel surface? (I have no drill press)

Clive

You only need to stop the drillbit from slipping, a couple of layers of masking tape (if you have any  ;D) will allow the bit to grip

Made some progress this morning with the bike! Coils back on, front brake caliper, rear brake pedals, kick start, headlight casing, speedo cable, and then..................

offered up the exhaust, went to put the collars on the bolts, and they needed some 'persuasion', realised, I then needed to take them back off as they weren't sat quite straight, and they're stuck fast!! There's not enough room to get behind them to give them the same persuasion back off!!!!

Any ideas as to how I'm can get these back off??

Clive

Well, got it back off, with some wrecking bar action!! :o :o Front of the engine now needs another lick of paint!

A couple of pics showing progress!

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day261.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day262.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day26.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day263.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day264.jpg)

Clive

Didn't realise how dusty it had got!!

Clive

It's looking very tidy Clive.

Thanks buddy ;D

Had a productive day today!!

New handlebars were drilled, re-wired, and mounted on the bike! That then meant I could re-fit the headlight and re-connect all the wiring! Couldn't resist then connecting a spare battery I had kicking about and checking all was good.............................and it was!!!! Even the high beam indicator that I'd put on the headlight cowl (can be seen in the pics between the dials) Chuffed to ****!!! Was slightly confused at first when the main beam, high beam, horn worked on the first click round on the ignition, but not the side, or tail light. These worked on the second click, but not the ones that worked before ??? ??? Now realise, and I hope I'm right and stand to be corrected if need be, that the side light and tail light are on permanently when the bike is running, and the rest then take their power from the charging system!!

Really not much left now, mainly bodywork and paint (tank, front mudguard). Still need to get a clutch cable, throttle cable, battery, banjo bolt pressure switch, and wait for my seat to arrive!!!!

Clive

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day271.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day27.jpg)

Hiya I spotted these on EBay and thought of your project...Voodoo...
http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=280479144186&ssPageName=STRK:MEWAX:IT

Cheers buddy, although I'm sorted for handlebars for this build, you can never have too many handlebars!!! :D

Did a bit more investigating on the lights thing. The second click is definitely a 'park' position as the key can be removed. I reckon, when the engine/alternator kick in, the side/tail lights will then work!?!?! Only time will tell!!
Clive

http://www.motuk.co.uk/mcmanual_110.htm
does this help?

Not really buddy, but always good to have as reference, cheers!!

Clive

Right, studied the wiring diagram, and switch diagrams long and hard, and reckon it's okay! Will give it another go with the new battery, which should be here by the time we get back from Berlin on Sunday!!

Clive

SSSHHhhh  .......  you never know whose listening  ...   ;D

  ..  Hagar  ..   ;D

Same here  ???, but I have to work with it every day (Only the car these days)

hi clive made mould and making your seat tonight will send you a pic tomorrow to confirm its the right one

Cheers buddy, email received, and sent reply!!

Clive

Lighting problems sorted!! Did some serious fault diagnosis today, and found a loose wire deep in the fusebox!! One of the only bits I never replaced!!!!! ::)

Fitted and adjusted the clutch and throttle cables as well, so I reckon all that's left is:

Seat painted and on, when it arrives from the good Mr Madron
Finish the paint on the tank
Fit front brake switch, and bleed brakes
Fit new battery
REMEMBER to put oil back in!! :D

then...................MoT!! (After trying to start it, get annoyed, swear, kick it, take it apart to sort out why it won't start, put it back together etc etc)

Clive

That's great progress Clive. Finished with more than a month to go before the Basingstoke show.  :)
I seem to be going backwards with my projects, making no progress at all.
Maybe if I just left my trike by your garage door, the build fairies might finish it for me.  :P

the bits promised from the 440 are ready to pick up when your ready ;)

Cheers buddy!!! :D You around on Sunday early evening?

Clive

i,ll be around not a problem will have the kettle on ;)

Quick photo update on this. Seat from Mr Madron adjusted slightly, and just dry mounted before paint!

I now need to source a small rear light as the original is TOOOOO big!!

Clive

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/IMG00021-20100325-1004.jpg) (http://s915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/?action=view&current=IMG00021-20100325-1004.jpg)

Ive got a cats eye tail lamp if any use to you?..Same as the one on this chop,it was chrome but its now painted Black...Also got a couple of small round tail lights knocking about......Voodoo....

Thanks buddy, but I think even that'll be too big!! :-\

I've found one on good old Fleabay, that's now winging it's way to me!!

Clive

cool looking bike Clive, I would make room for that in my garage  ;D ;D

Hi clive,Tidy looking cafe racer and i love the paint job.

Thanks Dai, hopefully some more photo's of the paint soon!

Shaun, looking at the things that come out of your garage, I'll take that as a great compliment, thanks buddy!!

Clive

I'VE FINISHED, I'VE FINISHED!!!!!!!! ;D ;D

Got it all back together, fuel in, and after 44 kicks, it started!!!!!!! (Then ran for about two minutes before dying. Not sure what that was all about, more investigating on Sunday. Advice/suggestions greatfully received!!)

47 days!!!!

Clive

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day47.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day479.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day478.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day477.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day476.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day475.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day474.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day473.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day472.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day4710.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/Day471.jpg)

that is so sweet, makes me hanker for an old 360 if someone has one going spare  :-* :-* :-*

Cheers Shaun!!! ;D








Now......where did I put that chopper?

Clive

You made a very nice job of that mate,be good to see it up close......Seeing that finished makes me wonder if I should keep my little XS Custom and bobber it lol....Voodoo...

yep you should  ;D ;D

Well done Clive great job.Did you get it started today.I think shaun may have mistaken me for someone else, The bikes i was involved with where Race Bikes back in 1974 to 1983.I then got married and was unable to dedicate so much time.Check out [R.G.B.racing squeezing the most out of parallel twins for over 30 years] dai  :)

No mate, ended up at the Salisbury MAG meet (by car), and then had to crack on with a helmet that should have been painted for a customer a week ago!!!!! (WWII bomber theme, pin-up etc) Got the basework done on it, and hopefully get on with the artwork tomorrow, as well as getting another go at starting the cafe!

Clive

(http://i915.photobucket.com/albums/ac360/533clive/PICT0001.jpg)
(http://i915.photobucket.com/albums/ac360/533clive/PICT0002.jpg)

Nice paint as ever....Wierd thing is I was going to paint up one of my full face helmets with the metal plate design but guess i will think of something else now...Voodoo...

Why? The aging/rust is great airbrush practice! I use transparent black, and a mix of bronze pearl and candy rootbeer!

Anyway, I'm now itching to get the bike on the road, now it starts, so phoned DVLA to see where the registration document is. Guess what, it went in the post this evening!!!! Wonder how much longer it would have taken if I hadn't phoned!?!?!?!

The reason it wasn't starting was this:

(http://i915.photobucket.com/albums/ac360/533clive/Cafe%20Racer/PICT0026.jpg)

This is a small sample of the fuel drained from the tank and carbs. It's about half fuel, half water, and half ( ???) rust and gunk!!

Clive

Yep that will sure make it hard work to try t start lol....on my chop i have a clear fuel filter and everytime the bike sits for a few days it fills up with fuel that is almost tango coloured lol...soon as ive started the bike it flushes that through and then the fuel runs as clear as it should be.......Glad its all coming together for you now....Voodoo......

Can anyone tell me the purpose of the second throttle cable on these sorts/age of bike?

I'd fitted the first, that operated in the correct sense, opening the throttle when the twist grip is turned, and then it would, albeit slowly re-un-twist (???) the grip as the carb spring kicked in and closed the throttle. When the second was fitted, the throttle, and grip stays put where it is when twisted.

As far as my tiny brain can work out it's not actually doing anything (except adding friction to the whole operation)! When 'throttle open' it's being pulled, when the spring is closing the throttle, it's being pushed back up inside the outer cable. Surely the first cable does all the work. Pulls the throttle open when twist grip is turned, and via the spring pulls the grip to the shut position when released!

Clive

I may be wrong but I think the two cables are meant for a push/pull arrangement instead of using a spring at the carb end, positive shut off.

I always thought the same, though I don't think I've ever had a bike that's had 2. Are you using the throttle unit & carb from different bikes?

No buddy! Completely standard set up!!

Clive

Sorted!! Having completely gone through each component in turn in the whole system, it turned out to be.........












Wait for it















The end piece of the rubbergrip rubbing on the end of the handlebar tube!!!!!!!!!!!! >:( >:( >:( >:( >:( >:( >:(

Clive

Simples!

MoT is turning into a saga on this!

Booked it in on monday, started fine, bumped it off the driveway onto the road to the sound of a big CRAAAACK!!! Number plate cracked by tyre!!

Ordered a new one, and built two little brackets to tilt it to give more clearance!

New plate arrived on weds, with a letter missing!!!! Phone call made and another put in the post!

Arrived today, fitted, and off to the MoT centre! Great bunch of motorcycle orientated MoT'ers there, and very professional!!

Failed on:

Play in head bearing - tightened
Revs increasing on full right lock - cable re-routed
Front brake binding - re-stripped and assembled
Front brake lever touching the bar when pulled (my fault for fitting one off a 125!!) - ordered a right one...hopefully
Swing arm bolt loose!!!!! - tightened
No 'bounce' in the front forks!! (I'd over filled them!!) - drained and re-filled with the CORRECT amount of oil
Exhaust gases escaping from manifold (again, my fault, forgot the gaskets!!) - ordered

Everything fixed, except the exhaust gaskets, and front brake lever/master cylinder, but these are both winging their way to me as I type!

Clive

Not too bad at all then as its all minor things....Good luck on the retest...Voodoo...
Oh if you get stuck for the brake lever ive got a couple of complete GS front brake set ups you could have one of those to get your mot with........

I thought it was only me who had luck like that!
Good luck for the next attempt.  ;)

I'd just thought I'd let everyone know, I'm a complete F**king idiot!!!!! I was getting really annoyed with the fact that none of the brake master cylinders I had worked.................. until I finally worked out that they work on a vacuum system!!??!!??!! I now have a working front brake. What a Knob!!!!!!!!!

Mr Toad, I now won't be requiring the cylinder you so kindly offered!! You must feel by now that I'm avoiding you!! :D :D :D :D

MoT booked for tomorrow.....again!

Clive

Fingers crossed Clive.

Vacuum system??????

Maybe not the right words, but didn't realise it had to have a pressure differential across the valve to be able to draw fluid through, thought it was supposed to pump it through!!!

Anyway, MoT passed ;D..............................but not without one more kick in the b**locks from the bike!! It decided to blow the main fuse two miles from my house on the way to the MoT! So I had to push it back, sort out the fuse (although I carry a spare, I didn't have the tools to remove the seat!?!?!?!), and then ride up there again!!

Clive

At least it passed! That's good news mate. Well done.