1982 CB900 Bold'or Transformation Project Part 2

So we begin…….

The old CB900 looked in pretty good shape in the pics taken prior to starting. It’s amazing how covering up all of the demons with matt black paint can trick the eye.

The paint is peeling everywhere, engine and frame…..literally everywhere !

So looking at the inspiration pics I had a good idea of what I wanted to achieve.

See through frame and engine similar to this Café Racer Dreams creation.
Front end from this also CRD project.
Back to it’s roots with a paint job that reflects the original 1982 CB900 F2.
First task is to remove all of the bits and pieces under the tank and seat. Side covers, electricals and battery and the frame that held all of this in place. The previous owner had already removed the air box and attachments to the carbs replacing with pod filters.
Then to design and build the hidden box that will hang in the frame under the seat to hold and hide the Lithium-ion battery and all the electrical parts. Made from Galvanised steel sheeting, it took a while to get a design that would hold it all, fit under seat and give easy access to all the parts if needed.
The café racer seat that I have chosen has a larger than usual hump on the back. This adds the versatility of being able to carry a pillion comfortably if needed and gives a bit more length over the rear wheel for meeting the legal requirements.
It needs to fit and be held in position so that it will be in alignment with the frame and tank. This meant I needed to remove the rear part of the frame seat mount and replace with a mount that would hold the back of the seat a little lower. Front of the seat needed a lock in mount that would hold the seat to the frame in a position that had the front of the seat close to the tank.
Now it’s tome to take off all the front end
  • Indicators (1)
  • Headlight (1)
  • Speedo and Tacho (1)
  • Switches and controls (2)
  • Handlebars (1)
  • Front wheel (2) and fender (3)
  • Forks (2)
  • Headers and Exhaust (2)
Most parts are being replaced with new parts (1), some are being stripped back and painted (2) some modified to look a bit more modern (3).
One little issue that stalled the process was the valve stem for the air adjustable front forks. To remove the handlebars the valve end also needed removal. But this one had other ideas. WD40 didn’t help, neither did heat. In the end I decided to remove the whole fork cap and deal with the suspension springs. Something that I was wanting to avoid but, it turned out that it was what I should have done, right from the start.
Once painted it was time to put it all back on. When putting on the forks it was time to also fit the fork boots, new headlight mounts and clip on bars. The fender is being re-modelled and painted and will go back on a little later.
With the front end back on, it’s time to attack the engine and rear of the bike. Look out for information about this in Part 3.