An 'old' newbie restoration

[modelman]

Hi guys & gals, been retired for 4 years now so have time to play with some 'toys'!
Been in light & heavy engineering of one sort & another, so have a rough idea what I'm doing & have the complete set of hammers to prove it!!
Right, just acquired a 1965 ( I think ) CB77, its an import from somewhere in the US, warm,dry & sunny by the state of it, but I've never had a Honda before, & have been biking for over 60 years,
( I was a 'rocker'with a 62 pre-unit Bonneville & the Ace cafe in London was my local hang-out)
So, this bike was seized solid, pulled the engine out, started to strip it but couldn't get at the split-link on the cam-chain, so off with the tensioner, head studs out, rockers & shafts out, popped the 2 piece camshaft, then off with the head, only to find it rusted solid in the barrels.
Since the case-castings are so flimsy, I didn't want to start whacking away & risk damage, so I filled the bores & head with grease, got a pair of M12 x 1.25 bolts, drilled & tapped both & fitted grease nipples, these were fitted in place of the spark-plugs. Head re-fitted & bolted down tight.
Removed the lower case & upturned the engine on the bench & started 'pumping' the grease-gun, it took over 3 hours, every gun-stroke resulted in a high-pitched 'squeak' a puff of grease-vapour from under the pistons & a few thou of movement!!
Finally the crank assy & pistons were out & no damage.
Apart from the bores being beyond it, the rest of the internals are like new, very clean with no rust, discolouration or apparent wear.
New replacement liners/pistons etc ordered from the Us along with about a grands worth of other bits & pieces.
Going to enjoy this one.
What a great site this is.
Try'd to post some pics, but can't for some reason

[PhilD]

Hi modelman and welcome to the forum. Glad to hear of another CB77 restoration in Yorkshire . I am in Leeds and also retired. Just finishing my 1964 CB77 restoration with a CB72 to follow. I'm happy to help you with manual, parts list and advice if you need any help.Just get in touch.
Phil D

[PhilD]

Hi modelman and welcome to the forum. Glad to hear of another CB77 restoration in Yorkshire . I am in Leeds and also retired. Just finishing my 1964 CB77 restoration with a CB72 to follow. I'm happy to help you with manual, parts list and advice if you need any help.Just get in touch.
Phil D

[G-Man]

Modelman

Welcome! Great technique. Did you use any heat?

Looking forward to your next post(s). You are lucky that the rest of the motor is good. This was one of mine......

I could have helped you with liners etc...

G

Hi guys & gals, been retired for 4 years now so have time to play with some 'toys'!
Been in light & heavy engineering of one sort & another, so have a rough idea what I'm doing & have the complete set of hammers to prove it!!
Right, just acquired a 1965 ( I think ) CB77, its an import from somewhere in the US, warm,dry & sunny by the state of it, but I've never had a Honda before, & have been biking for over 60 years,
( I was a 'rocker'with a 62 pre-unit Bonneville & the Ace cafe in London was my local hang-out)
So, this bike was seized solid, pulled the engine out, started to strip it but couldn't get at the split-link on the cam-chain, so off with the tensioner, head studs out, rockers & shafts out, popped the 2 piece camshaft, then off with the head, only to find it rusted solid in the barrels.
Since the case-castings are so flimsy, I didn't want to start whacking away & risk damage, so I filled the bores & head with grease, got a pair of M12 x 1.25 bolts, drilled & tapped both & fitted grease nipples, these were fitted in place of the spark-plugs. Head re-fitted & bolted down tight.
Removed the lower case & upturned the engine on the bench & started 'pumping' the grease-gun, it took over 3 hours, every gun-stroke resulted in a high-pitched 'squeak' a puff of grease-vapour from under the pistons & a few thou of movement!!
Finally the crank assy & pistons were out & no damage.
Apart from the bores being beyond it, the rest of the internals are like new, very clean with no rust, discolouration or apparent wear.
New replacement liners/pistons etc ordered from the Us along with about a grands worth of other bits & pieces.
Going to enjoy this one.
What a great site this is.
Try'd to post some pics, but can't for some reason

[modelman]

Hi G-Man, I did try heat at first, but it didn't work, then I thought of the grease!!
If the pics work, you will see how nice it is, but it will still get the full resto job!!

BTW, how could you have helped with the liners etc.?

That one of yours is/was in a bit of a state, not sure I would attempt that!






https://www.flickr.com/photos/lawriespi ... 019391411/

[Steverino]

Those mufflers look very nice. I got nosy and looked at your Flickr pics.
Steve

[G-Man]

Modelman

I have some nice barrels with good liners and even the odd NOS liner....

Here's the 'after' for that CB77 motor... Crank is NOS.




G

BTW, how could you have helped with the liners etc.?

That one of yours is/was in a bit of a state, not sure I would attempt that!


https://www.flickr.com/photos/lawriespi ... 019391411/