Here we go again - Off Road CL160 Pickup

PugMug

Veteran Member
Joined
Feb 19, 2024
Total Posts
186
Total likes
143
Location
Los Angeles, California, United States
So a few weeks ago I picked up another project 160. This time it’s a CL160 that’s been modded a bit for off-road riding, which is pretty cool since that was my intention for my original CB/CL160 I picked up a while back.

A little backstory- this bike came up for sale on FB marketplace probably a year ago. From what I could gather the owner had passed away and his children were liquidating his estate. It appeared to have been sitting since the 80s, at which time someone started taking it apart as it was missing its carbs, air filters, throttle/controls, petcock, etc. It was also missing all four tappet covers so I was figuring the head was in bad shape. The tail light assembly and center stand were long gone as they were probably removed for off-road. The pictures were sparse, but it was obvious it had a completely different front end and some aftermarket/longer rear shocks.

Since I already had my CB160 project bike that I was turning into a CL160D and the asking price was way too much IMHO, I just watched this from afar until it eventually sold after a handful of months. I was sort of bummed but at the same time a bit relieved and I moved on.

So then about a month ago, the bike comes up for sale again at half the price. It sounded like this new owner didn’t realize the amount of time, effort, and money it would take to get the bike functional again, so they wanted to unload it and were highly motivated. They also said they opened up the motor and their assessment was that it would need a full rebuild/motor swap. At this point the price was looking pretty good, but I still sort of let it sit there because I didn’t know if I wanted a third 160 sitting in my yard… Then one morning I noticed the seller dropped the price again, so I felt like at this point I couldn’t pass this up and at the very least could use it as a parts bike. I reached out, got a bit more info on the bike and threw an offer at him and he immediately accepted and a few days later I had the bike in the back of my CR-V (in pieces).

IMG_3011.jpg

Once I got it home I put it back together so I could sort of give it a decent assessment. It’s got Cerani forks (and I guess triple clamps?) on it which is pretty sweet. The PO did mod/cut the steering stop/damper mount on the frame so the lower triple clamp would clear- that’s a bit unfortunate. On the rear it’s got some equally cool Curnutt Shocks- the shafts are pretty toasted but still cool. (Side note- I always wanted a Foes DH mountain bike back in the day and I remember they all came spec’d with Curnutt shocks…) As I mentioned before, it is missing some key items that I’ll need to get this thing running again, but I’m pretty excited about this one.

IMG_3013.jpg
IMG_3014.jpg
IMG_3019.jpg
The seller had bike sitting outside in his yard for the last six months (with no carbs, no tappet covers, and no spark plugs) and we’ve had some decent rain out here in SoCal, so I’ve already got the motor back out and opened up on my workbench. There was water inside the bottom end and the left cylinder had some surface rust/rusty water sitting in it, but it should clean up okay. I haven’t been able to get the head apart yet as I’m fighting with the screws on the right cam base cover.

The plan is to get this motor evaluated and maybe buttoned up/ready to run before I jump back to my other 160. Or maybe try to work on them in parallel- we’ll see…
 
PugMug you are “The Man”.!!! Three 160s at once!!! This one deserved a rescue and should be awesome. A custom off road CL160. In the photos you seem to have the side stand and foot rest and the real CL skid plate which are hard to come by. I keep plodding along slowly on my CL160 D between family obligations and responsibilities! I will follow and learn!!
 
It’s got Cerani forks (and I guess triple clamps?) on it which is pretty sweet.
Quite the suspension upgrade for a bike from that era, more travel in front than the early SLs.
On the rear it’s got some equally cool Curnutt Shocks
There's a name I haven't heard in decades, wow.
 
That’s an interesting find! I’d be tempted to do a really stripped down dirt-forward scrambler for some of those high desert riding areas out there.
 
PugMug you are “The Man”.!!! Three 160s at once!!! This one deserved a rescue and should be awesome. A custom off road CL160. In the photos you seem to have the side stand and foot rest and the real CL skid plate which are hard to come by. I keep plodding along slowly on my CL160 D between family obligations and responsibilities! I will follow and learn!!
Yeah honestly that skid plate was a huge selling point- that and the both side covers being intact, and yes the foot bar with the side stand. If I wanted to I could sell all that stuff and easily make twice as much as I paid for the whole bike, but I want to ride this thing!
 
Quite the suspension upgrade for a bike from that era, more travel in front than the early SLs.

There's a name I haven't heard in decades, wow.
Yeah the original owner must've been fairly serious about riding to outfit the bike with this setup. I'm curious how it will feel compared to my brother's SL175 out in the dirt.
 
That’s an interesting find! I’d be tempted to do a really stripped down dirt-forward scrambler for some of those high desert riding areas out there.
That was my original intention with my first 160, so it's nice somebody else has already done some of the heavy lifting :) For now the plan is to get it running and actually see how it is in the dirt- I may realize this was all a big mistake lol.
 
Yeah the original owner must've been fairly serious about riding to outfit the bike with this setup. I'm curious how it will feel compared to my brother's SL175 out in the dirt.
Front forks should feel better and truly have more travel, I owned an SL175 new and though the front forks were far better than anything I'd owned to that point, they weren't nearly as good as the DT1s and RT1s of the day so those Ceriani forks should be a good upgrade.
 
Last edited:
Likely an old GM coil. There could be some fun “mods” under the covers there…
 
PugMug I was looking back over previous posts of your CB160 and thisCL. Noticed you have “Candy blue “ side covers and the CL a “Candy blue” tank!! Are any of these original color or do you think they are repaints?? Reason I ask is mine is definitely a repaint.. poor quality and I plan on redoing my tank. Didn’t know if you perhaps had plans of trying to match original paint to a modern automotive paint color at a local paint shop with color scan??? I know Candy paints are hard to match in modern base coat clear coat systems. If you do try I would love to know your paint code they come up with to color match. Here is my current tank color when purchased. Definitely not correct color in my opinion.IMG_0579.jpeg
 
PugMug I was looking back over previous posts of your CB160 and thisCL. Noticed you have “Candy blue “ side covers and the CL a “Candy blue” tank!! Are any of these original color or do you think they are repaints?? Reason I ask is mine is definitely a repaint.. poor quality and I plan on redoing my tank. Didn’t know if you perhaps had plans of trying to match original paint to a modern automotive paint color at a local paint shop with color scan??? I know Candy paints are hard to match in modern base coat clear coat systems. If you do try I would love to know your paint code they come up with to color match. Here is my current tank color when purchased. Definitely not correct color in my opinion.
All the blue bits on this CL are repaints and not metallic at all. The blue paint is flaking off the tunnel and bottom of the tank exposing the original silver color. There are areas on the side covers that are revealing the silver paint underneath as well.

I just assumed all 3 blue metallic side covers I got with my CB were repaints- two of them have a lot of silver showing through in spots. The third one does look pretty good though and could be original? Maybe I'll give them all a closer look this weekend...

I'd like to get everything back to its original silver color, but honestly they'll probably stay blue for a very long time.
 
PugMug, Thanks for checking all those parts…. It will be a while before I get ready to paint mine so maybe I will run across an original Blue to try to match.
 
PugMug, Thanks for checking all those parts…. It will be a while before I get ready to paint mine so maybe I will run across an original Blue to try to match.
Not to hijack PugMug’s build thread here, but the period correct blue is (or would have been) a Candy Sapphire Blue, IIRC from my compatible paint code rabbit hole. Marbles Motors has the paint, but it think it was popular enough that some of the other paint houses might have it as well.
 
PugMug, Thanks for checking all those parts…. It will be a while before I get ready to paint mine so maybe I will run across an original Blue to try to match.

So here are my 3 blue side covers. I think I was mistaken when I said two of them were definitely repaints- obviously the bottom one was, but I thought the top left was as well, but the more I look at it... That one and the top right could be original?

IMG_3107.jpg

Here's another shot of the two not in the direct sunlight:

IMG_3108.jpg

I guess I assumed the chipped areas revealing the silver meant it was a repaint, but maybe that's just the base color... Here's a shot of the back of both:

IMG_3109.jpg
 
Thanks for the update! Top right is in great shape if original!! Both of the insides appear silver. Would the inside have also been painted blue if original?? I’m asking as I certainly do not know.
 
Thanks for the update! Top right is in great shape if original!! Both of the insides appear silver. Would the inside have also been painted blue if original?? I’m asking as I certainly do not know.
The insides are sort of a light gray- might just look silver in the photos. I doubt they'd paint the insides blue, but honestly I don't know.

You've got me sort of liking the blue now. I might go for the blue color scheme if I could find a reasonably priced blue tank...
 
The insides are sort of a light gray- might just look silver in the photos. I doubt they'd paint the insides blue, but honestly I don't know.

You've got me sort of liking the blue now. I might go for the blue color scheme if I could find a reasonably priced blue tank...
The air cleaner covers were never painted blue, they were always silver, with the exception of the all-white CB160 variant.
 
I was able to get the motor opened up a few weeks ago, just didn’t have time to post it all up here. Anyway here’s what I’m up against. Overall it seems to be pretty good- minus the water that got into it before I picked it up. Not a huge amount of sludge in the cases, although I still need to get the oil separators out and see how things look under those. The water did some damage to the left cylinder, but I think a hone job will clean it up good enough. Maybe it’s just me but the cross-hatching on the cylinder looks pretty aggressive? Nothing noticeably wrong with the transmission or crank- I’ll do my best to clean the crank up regardless.
IMG_3074.jpg
IMG_3075.jpgIMG_3078.jpgIMG_3084.jpgIMG_3092.jpgIMG_3093.jpg
IMG_3094.jpg
 
Not too shabby - all things considered. Kind of looks like there was a recent rebuild with the .50 overbore pistons. That hone is questionable at best - I guess whomever did that work doesn't believe in lubrication. It'll be interesting to see how it cleans up.
 
Not too shabby - all things considered. Kind of looks like there was a recent rebuild with the .50 overbore pistons. That hone is questionable at best - I guess whomever did that work doesn't believe in lubrication. It'll be interesting to see how it cleans up.

Okay so it's not just me then. Here's a close up of the right side...
IMG_3080.jpg
 
It looks a bit rough for sure, but cameras can be tricky sometimes. Does it feel as scratched as it looks?
 
Life has been throwing me curveballs so I haven’t touched any bike projects in months. I did get a tiny bit farther with this motor a while back but neglected to post any updates here.

The cylinder bores don’t feel as bad as they look- I’ll probably give them a very light hone to “smooth” them a bit (for my own sanity), but I think they’re probably okay.

I got the cam out and as suspected it’s got a lot of surface rust. In the one pic it looks like a big gash in the lobe, but that’s just dirt.IMG_3126.JPG
IMG_3127.JPG

I cleaned it up with some 0000 steel wool and it looks 100% better now.

IMG_3129.JPG


I want to get this crank into a kerosene bath so it can marinate while I rebuild the head and make sure that's all set- hopefully I can get some time this coming weekend to get back into this and keep the momentum going again...
 
Got in a little time on the motor this past weekend. Found a couple of issues.

First, one of the cylinder sleeves is raised up a tiny amount- measured it at .25mm. I'm trying to figure out the best way to attempt to get it flush again- thoughts?
IMG_3311.jpg

Second, I found a small crack on the bottom of the lower case- there's no other damage to suggest it was an impact crack (the bike had the skid plate when I got it). It doesn't appear to go all the way through to the inside of the case.

IMG_3316.jpg
 
I have no personal experience with the 160's, so let me say that up front.
  • I feel like loose sleeves have come up a couple of times recently with these motors. Maybe if you heat the block (as in an oven) it will drop back in or could be pushed down easily.
  • As for the crack, are you talking about the the jagged line just above and to the right of that rectangular section? Are you sure it's actually a crack and not a surface imperfection from the original casting?
 
Last edited:
I have no personal experience with the 160's, so let me say that up front.
  • I feel like loose sleeves have come up a couple of times recently with these motors. Maybe if you heat the block (as in an oven) it will drop back in or could be pushed down easily.
  • As for the crack, are you talking about the the jagged line just above and to the right of that rectangular section? Are you sure it's actually a crack and not a surface imperfection from the original casting?
I don't think my wife will let me put the block in our oven- maybe I should look into a cheap little toaster oven...

Sorry I should've highlighted what I am talking about. The red circle is the one in question. I did think it might be a casting mark that split open a little- I've seen some casting imperfections, but this one seemed a little different.

The green circle is definitely a casting imperfection- that one is a slight indent, but doesn't have the depth and jaggedness the red circled one does. I'll try to clean it up a bit more and have a look with a magnifying glass to see if I can get a better read on it...

IMG_3316_highlighted.jpg
 
I don't think my wife will let me put the block in our oven
Maybe if you ask nicely she'll put the block in the oven for you. Degrease it, wrap it in tinfoil, and turn the hood fan on high.

I should've highlighted what I am talking about. The red circle is the one in question.
I didn't even notice the green circled one. Was looking at the one in red. I would guess it's a surface defect, but I can only guess.
 
Maybe if you ask nicely she'll put the block in the oven for you. Degrease it, wrap it in tinfoil, and turn the hood fan on high.


I didn't even notice the green circled one. Was looking at the one in red. I would guess it's a surface defect, but I can only guess.
Yeah the red circle is the one in question- I did have a quick look again this morning and I am thinking it is probably just a slightly more aggressive surface defect.


BBQ on low works...
Good idea!

Any thoughts on an optimal "low" temp? 200-300 degrees? I've got a gauge on my BBQ so I can dial things in pretty close...
 
Yeah the red circle is the one in question- I did have a quick look again this morning and I am thinking it is probably just a slightly more aggressive surface defect.



Good idea!

Any thoughts on an optimal "low" temp? 200-300 degrees? I've got a gauge on my BBQ so I can dial things in pretty close...
375-400 is the best range for steel/aluminum interfacing parts. I'd second the BBQ method - it'll stink up the house unless the part is seriously degreased and those 160 cylinder jugs have those weird blind undercuts that you stand zero chance of actually cleaning the gunk out of.
 
Also, does anyone have a right side intake manifold they don't need? I have two lefts, but no right.

I don't need it yet, but figured I should put the word out now as I'll need it eventually...

What size is stamped on your carbs? I have a spare set of carbs stamped "20" that I picked up from a buddy today knowing you were looking for a right side manifold but I note that they are the exact carbs I have on my CL175K0. I also note the part numbers are different for the CL160 as compared to the CL175K0. If we figure out you can use it I'll send it to ya
 
What size is stamped on your carbs? I have a spare set of carbs stamped "20" that I picked up from a buddy today knowing you were looking for a right side manifold but I note that they are the exact carbs I have on my CL175K0. I also note the part numbers are different for the CL160 as compared to the CL175K0. If we figure out you can use it I'll send it to ya
175s and 160’s aren’t a direct fit.

I may have one but I’d need to dig around.
 
Back
Top Bottom