Building a Honda CA95 from Scratch-Where's The Bike Now?

Spokes · Post by **Spokes** » Sun Mar 21, 2010 5:07 pm

Thanks I will remember to check out the site next time I am in need. But 9 times out of 10 she makes me a key while I wait...and I have not spent over $5.00 for a pair. It is a good ole' boy network down here in southwest KY and you can't beat the hospitality.

gbaumgratz · Post by **gbaumgratz** » Mon Mar 22, 2010 4:05 pm

Sure does sound like a deal - couldn't get most of the locksmiths is this area to unlock their front door for $5 much less make a key for a lock when you have none. Anyway - just passing along the source if there is a list somewhere. Plus it's nice to have the shiny new actual 'Honda' keys sometimes.

Spokes · Post by **Spokes** » Tue Mar 23, 2010 8:25 am

Update time again!

Got in my front forks...again, same story, "only some dents" Well, back to the restore mode. The headlight bucket has holes drilled into it, front fork was hit and ground down one shock tower, and no shock tower mounting bolts or bearings.

But once again, ain't beat down completely, forks straightened out and with the headlight bucket, off to the sandblaster. The headlight bucket will be repaired and steering roller bearings found. The races were perfect, so no cry there. Found another shock tower and that should be delivered in a week, and now missing only 1 part...one shock tower bolt.

Wheels should be here today, and the white complete white CA160 should be here in about 10 days. Pics coming soon. Once a rear swing arm is found, a shock tower bolt and the rest of the ebay hardware, junk or not, arrives she will be up on two wheels.

aaron7 · Post by **aaron7** » Tue Mar 23, 2010 8:32 am

I have a complete front end if you need anything. Let me know and I'll add it to the box!

Sam Green · Post by **Sam Green** » Tue Mar 23, 2010 8:39 am

Spokes wrote:Update time again!

Got in my front forks...again, same story, "only some dents" Well, back to the restore mode. The headlight bucket has holes drilled into it, front fork was hit and ground down one shock tower, and no shock tower mounting bolts or bearings.

But once again, ain't beat down completely, forks straightened out and with the headlight bucket, off to the sandblaster. The headlight bucket will be repaired and steering roller bearings found. The races were perfect, so no cry there. Found another shock tower and that should be delivered in a week, and now missing only 1 part...one shock tower bolt.

Wheels should be here today, and the white complete white CA160 should be here in about 10 days. Pics coming soon. Once a rear swing arm is found, a shock tower bolt and the rest of the ebay hardware, junk or not, arrives she will be up on two wheels.

Damn Spokie, you're gonna be a buzzy bee

Do you ever get to your local drag strip? I might see you down there one day if you do.

Sam.

Spokes · Post by **Spokes** » Tue Mar 23, 2010 9:45 am

Aaron, Sam

Aaron, Thanks, just one lonely shock tower bolt would be great. Your stainless bolts and special tap should be there today if not tomorrow!

Sam, I have not been to the track here in Bowling green, My days of drag racing was in Ohio in the early 1990's at Norwalk Drag Raceway.

Should you be here in BG. Just let me know, just a 20 minute trip for me.
Always liked the smell of alcohol exaust fumes, burning rubber combined with noise........good vibrations....

Spokes · Post by **Spokes** » Thu Mar 25, 2010 9:53 am

Finally got a good used wire harness dated 1964, so all I need to do is unwrap the wires check for burns and add turn signal wiring into the harness and rewrap and store until ready to install. The 1st harness recieved was bad but some good color coded wire was salvaged and used to replace bad wires on the coil and starter solinoid. The spark plug caps are in and once the new spark plug wire arrive the old spark plug wires will be replaced and new caps fitted. Coil had an OHM reading of 2.8 so I trust that with the updated wire it should be good to go.

I got in a new headlight, 6v replaceable bulb type...sweet. The bike should be ready for 1st pic's on two wheels in a few days.

The white CA160 is on the truck being shipped and expected within a week. An additional thread will be started about the CA160 and it's transformation to a daily mild custom rider.

Smithers · Post by **Smithers** » Thu Mar 25, 2010 10:03 am

I'm tempted to make wiring harnesses from scratch for people who are restoring these bikes. If only I had the spare time.

Wiring is probably one of the biggest problems that people seem to be facing when restoring them. I'm talking about the normal enthusiast who wants to get one running... not the pros here.

Spokes · Post by **Spokes** » Thu Mar 25, 2010 11:53 am

If we could only play without work....

It would take about 10 hrs to build a fixture then get the ignition plug from Hondaminitrail.com ,assorted ends and wire.

Once a fixture is made and an inventory of color coded wires and connectors at hand, you could build a new harness in about an hour.

Spokes · Post by **Spokes** » Sat Mar 27, 2010 4:58 pm

3-27-10 The bike now has the front forks and headlight bucket sandblasted, repaired and primered. Found good ball bearings and with the good races, able to mount the forks. The front suspension and rear forks will be in next week, so the bike will be on it's own wheels (shown). The coil and starter solinoid have been repaired. The 2nd set of wiring looks good and keys were made for the ignition and steering lock. New headlight delivered..

The engine rebuild will start next as well. The objective is to assemble the bike as is, make sure everything works, engine runs etc., and break the bike down for paint and tires.

The way the bike looks today 3-27-10
(picture here)

Spokes · Post by **Spokes** » Tue Mar 30, 2010 5:12 pm

Wheels on. Rear swing arm turned out good (thanks Aaron) The rear shocks are up side down but will work until better ones or better parts arrive.
The bike is taking shape, it is rolling inventory now.

In the back of the pic is my 68 CA160 just arrived today.
(picture here)

Spokes · Post by **Spokes** » Sun Apr 04, 2010 5:11 pm

Here is a before pic and a after pic of the engine build for the CA95. The case was cleaned and painted before assy. Painted 3 coats heat/fuel/oil resistant paint the 2 coats clear of the same. Paint cured 1 month.

When I started

(picture here)

Where I'm at now 4-4-10
(picture here)

Smithers · Post by **Smithers** » Sun Apr 04, 2010 8:57 pm

Ahhh now that's the way to do it! Awesome.

Spokes · Post by **Spokes** » Tue Apr 06, 2010 9:05 pm

Today was shock absorber day. Had two shocks with fair chrome lowers but no uppers, just got in some shocks with bad lowers and good metal uppers. I disassembled all the shocks and combined the parts. Result,two nice shocks. I have one extra bottom going to another forum member to do the same for him. I will make a thread about how to redo the CA95 shocks.

You can rebuild the CA95 shock, you can send out the lowers for rechrome or paint, you can make them any way you want.

Smithers · Post by **Smithers** » Wed Apr 07, 2010 7:37 am

Now how about the adjustment process in regards to the telelever front suspension? Is that what it's called? Front cantilever suspension... something like that. I just know my CA160 rides LIKE a Dream

but my 150 is definitely a little rough on the road in the front end. I've always wanted to do some adjustments up front between the two. I'm sure you'll get to that point soon.