CA77 Carb Rebuild

grom · Post by **grom** » Thu May 29, 2008 12:48 pm

I'm trying to bring a '64 Dream back from the dead. It has not run for at least 5 years. So far I've de-rusted the tank, changed out the fluids, put in new spark plugs and am planning to rebuild the carb. My question: is it easier to detach the throttle cable, leaving it on the bike, or just bring the whole assembly out? Thanks for any insight you folks can offer.

joeweir1 · Post by **joeweir1** » Thu May 29, 2008 8:21 pm

It is much easier to work on if you take cable off at the throttle grip.I have replaced them by unbolting the carb and dropping it and unscrewing the top.It's harder to thread it back on this way but I have done it many times.What are you using to rebuild it?If you use the kits off Ebay they are much different than stock and may require some tinkering to tune.I did this but then put almost everything stock back in my carb. except for the float needle.Keep us posted

grom · Post by **grom** » Thu May 29, 2008 9:55 pm

Yes, I'll be using a kit from E-Bay. I hope to re-use the stock jets. I find it odd that a rebuild kit would have different sized jets than stock, but that's just my opinion. Thanks for the advice on the cable, I'll see if I can snake it out without too much trouble.

joeweir1 · Post by **joeweir1** » Fri May 30, 2008 3:03 pm

I thought it was strange too.If your going to use the kits main needle you probably will have to move the clip up one notch(to the second notch) from the original position or you will run rich probably.I learned this from my experience.There are some old posts on this also on here in the carb section I believe.I'm not the only one who had to do this.Good luck.Joe

grom · Post by **grom** » Wed Jun 18, 2008 10:06 am

Thanks for the advice. I was able to remove the carb without much trouble. I snaked a wire through the body to help run the throttle cable back through. The original jets were both plugged, but I was able to clear them using just carb cleaner and the force of the spray. The original needle was worn, so I replaced it with the kit needle and moved the clip up as suggested. Unfortunately, I thought that I had a square bowl but I have a round one, so I'm waiting for the proper gasket to come for final reassembly. With any luck, the bike will be running by the weekend.

joeweir1 · Post by **joeweir1** » Wed Jun 18, 2008 7:33 pm

Just wanted to mention that I used the needle clip on the second notch with the jet provided with the kit not the original 120 jet.Not sure if you may be lean or rich with new needle and original jet.

grom · Post by **grom** » Fri Jun 20, 2008 9:46 pm

I appreciate the clarification. I moved the clip back to the original location on the needle. My gasket arrived today, so everything got assembled. I put the carb back on, resnaked the throttle cable and fired it up. The bike ran for about ten seconds, and sounded great. Then everything stopped. The headlight went out, the tail light went out, and the bike quit. I'm a little scared of what might have happened. The fuse from the battery is intact. Any ideas?