CA160 Cylinder Studs

Long story short, the CA160 uses two slightly-longer cylinder studs than the CB160 or CL160. This is because of the difference in how these motors mount to their respective frames.

When I rebuilt my CA160 motor, one of these longer studs was stripped and I had a helluva time finding a replacement.

I purchased a parts book a while back, and it has the proper parts numbers and diagram.

Rear-most center pair of studs: 90031-225-000
The other six: 90031-216-000

If you look closely at the top of this ca160 motor, you can see the longer studs.

Here you can see a CB160 motor, and the studs are the same length:

On my CA160 parts book, the studs are 21 and 21A here:

RIGHT:

 

WRONG:  

S90 Exhaust progress

Behold my shitty welding. The makerspace I belong to has a 220v wire welder, so that made it a bit easier to put this together.

I don't know what possessed the previous owner to chop out the battery box. Probably why this bike was only $150. Next time, I'm adding 'unchopped frame' to my list of requirements, right under 'titled'.

Anyway, I lucked into a nice piece of steel that fit the profile really nicely.

I threw this in the vice and bent it up just so a few times.

All the metal I could weld it to was bent all out, and it's impossible to get a damned pair of pliers in there to straighten it.

Looks like I didn't get a shot of the battery cage from inside and the tack welds. Oh well, it needs welded again. I had a look at my CL90 parts frame and the cage goes all the way across to the back and is welded there to give some strength to the frame. I think I'll take a piece of flat bar steel and do that. Not sure how I'm going to weld this in without melting the thin steel. Wish me luck.