Almost Finished...

Almost finished after 11 months.  I need to rebuild the fuel petcock and install it, connect the battery and start it up. Here are the before and after photos:

September 2012

August 2013

Fixing the Old License Plate

Here's what I did to the license plate for the blue SL90.  The plate had cracked badly just under the upper mounting holes as it was only mounted by the top two bolts - the constant vibration and flapping nearly cracked it all the way across the top.  It's hard to see in the top photo, but the cracks actually extend to the either side of the "CAL" on the plate.  So, I went ahead and had the cracks welded and ground (second photo) - you can weld the old steel 1963 style plates.  I also hammered out the dents and made the plate fairly flat again. Once the cracks were welded, I debated the idea of powder coating the plate black and hand lettering the yellow.  However, I kind of like the old weathered patina, so I painted the welded portions with a mix that approximates weathered license black (bottom photo).  I will touch up the yellow where the grinder took off paint (provided I can match it).

I couldn't save the stickers - the welder melted them...

I might change my mind and go the total restoration route - in the meantime, I will put my name on the CA DMV list for a reproduction 1963 style plate and see what happens.

Cleaning SL90 Carburetor - Part 1

My second SL90's carburetor needs a rebuild and I decided to clean it before disassembling it.  The carb was really gunked up.  I used to use Berryman's carb dip to clean carbs, but I don't like using flammable, toxic cleaners, so I tried Pine Sol based on some on-line posts on various motorcycle forums.  It's non-toxic, easy to dispose of, cheap and makes your shop smell like pine trees (or a janitors closet).

I used undiluted Pine Sol in a plastic container and soaked the carb for about 2 hours.  After soaking I rinsed off the Pine Sol and soaked the carb in clean water and flushed out the Pine Sol.

Before - fairly well gunked!

After soaking and a quick buff - I'm impressed with the Pine Sol, it removed most of the gunk, grease and dirt.

Now that I can see the screws and jets the next steps are: disassemble, clean jets and needle,  detail clean the bowl and crevices, replace gaskets, use compressed air to blow out the orifices and set floats...

Headlight Installed

I installed the headlight and hooked up the wiring (in the headlight bucket).  I cleaned all of the connections with contact cleaner and checked them all.  I still need to install the rectifier - I may have to replace it (we'll see).  I'm getting the tank and petcock set up for installation...

While doing the wiring, I found that my brake cable needed replacing due to its age.  I found that a CT70 brake cable makes an excellent replacement as it has the same stop switch configuration as the SL90 and the CT70 cable also has a gray casing like the SL90.

Front Wheel and Seat Logo

Progress!  I finally installed the good front wheel with new brakes and seal. The photos aren't the best (end of the day, low light). Replacing the rusted spokes and oxidized hub makes a real difference in looks.  

I installed the front brake, clutch, speedometer and throttle cables.  I also installed the instrument lights.  

I also stenciled the Honda logo on the seat using vinyl paint.  It came out "ok" and I learned some things about how to properly stencil in 90 degree F heat.

The logo passes the "3 foot" test...
Next up, finish the headlight and wiring, install the fuel line and tank logos, install a new petcock,  battery, fresh oil, fuel and get ready to attempt starting the beast.

Round Two (Preliminary)

 My blue SL90 is getting close to being finished and I'm lining up the parts to start "Round Two" (the red SL90)

I've been able to locate all of the "tins" for the red Sl90, including the side cover.  I'll start the body work soon and get the tins prepared for the Candy Red coating.  The metal parts look fairly 'beat up" by the usual sun exposure, rust and dents...

Handlebars

I had the stock SL90 handlebars re-chromed and I picked them up from the plater yesterday.  They are the last item that I decided to chrome.  I held off re-chroming them thinking the old chrome might be good enough, but when the handlebars were installed next to the freshly chromed parts, they looked pretty awful

Here's a comparison shot showing the freshly re-chromed handlebars (top) compared to what you typically find when searching for stock SL90 handlebars (rusty and sometimes bent).

Newly installed handlebars - note the headlight bucket full of wires. I'm waiting for some new 6 volt instrument light bulbs to finish off the wiring.  They are scheduled to arrive in two days along with the new wheel bearings for the front wheel.  You can see the black air intake boot (tube) attached to the air filter box.  The rubber was as hard as a rock and I could not install the boot on the carburetor as it would not flex.  I obtained a bottle of "Rubber Renew" and soaked the boot in it by placing it in a zip-lock plastic bag with the liquid.  After 48 hours, the rubber magically became pliable and flexible - almost like new - and I was able to install it with no difficulty.  

Advertising and Misc.

 Actually in the "rough country"

Gas Tank Emblems

I restored the Honda gas tank emblems while waiting for the front wheel bearings to arrive.

 Before

After

I repainted the emblems white, then I lightly sanded the letter faces and repainted them black, even though the original letters were a sliver gray (I could not get them to look right)

Same treatment for the wings (below), paint and sand (no black of course)

Now I'm working on restoring the carburetor intake rubber and making a new air filter element.

In the meantime, here are two more examples of modified Honda Sl90's for your viewing pleasre - one in the scrambler colors (red & silver) and a red SL90 with dirt bike fenders...

Rear Wheel Installation

I spent a few hours installing new wheel bearings, grease, seals, brake shoes and springs, the cush drive rubbers and all of the related parts for the brake and rear wheel assembly.

For reference, here's the rear of my SL90 in September 2012 - the starting point.

Here's what it looks like now (August 2013) - it's almost been 1 year!  I will need to install the drive chain and adjust the rear wheel and brake accordingly.  The rear brake works - the new shoes really hold.

The front wheel will be relatively simple compared to the rear wheel.  I thought I had wheel bearings in my inventory for the front wheel, but no such luck.  I had to order a set (and wait)...

Modified Honda SL90's

The red SL90 in my last post inspired me to look for modified or custom Honda SL90's.  Since I have an extra frame and parts, I wanted to get some ideas for what could be done with the SL90.  Here are some examples:

First up - a black and silver variation.  The bike looks basically stock with just the color change. 

 I noted that this black and silver SL90 is for sale (on Craigslist) in Alabama

 Next up, an SL90 disguised as a BSA thumper. The owner did a really great job of transforming the SL90 with some nice touches.

This BSA poser was also for sale on Craigslist several months ago.

Here's an interesting bitsa that demonstrates how an SL90 frame can be married to Postie and other parts to make a "cafe racer" style bike (check the swingarm and forks)  This one ended up being turbocharged as I recall...

Sl90 Chopper, "Easy Rider Style" (below)...