New Cb77 project

[olde-goat]

Great pictures. The actual button on my CA 77 starter switch is missing. Are these all basically the same size? Does anyone reproduce the button? Thanks

[GregMcN]

Hi olde-goat

I think you can still buy the button on its own from Honda for the CB77, part number 35317259300. I would guess it would be the same for the CA77 but I do not know.

[olde-goat]

I will have a look, thanks

[GregMcN]

Continuing with the electrical work, the next job was the rear brake switch. The internal contact seemed to work but the external wires were hanging on by a thread and the rubber cover could not be reused.



The external wires were resoldered and I found some 20mm diameter end caps that could be used to replace the cover. I know Clauss studios sell reproduction rubber covers but they are very expensive by the time they get to the UK so thought I would use the end caps for now and maybe replace at a later date if I order a few items from Clauss.





The spring and link had previously been sent away for zinc plating.

[GregMcN]

The last electrical job was the rectifier. The one I had was scrap and although I wanted to keep the project as original as possible given the low cost of modern regulator/rectifiers this seemed a better option than trying to find a good replacement. To keep it looking fairly standard I cut down the scrap rectifier, resprayed it and mounted the new regulator/rectifier underneath. This was harder than anticipated just because of screws clashing. The new reg/rect was wired up by joining the pink and yellow alternator output wires at the headlamp and fitting a separate fuse in the positive feed.





All the electrics seem to work, I have sparks and lights though the reg/rect is untested.

[GregMcN]

I did not have any exhaust collets, These can be purchased new, a set in the UK costs £50 which seems excessive for 4 fairly basic pieces of metal so I decided to try and make some. I purchased some 44.5mm OD, 2mm sidewall steel tube. I cut lengths of 27mm and about 3mm. Put a cut in the 3mm ring, spread it round the top of the 27mm piece and welded the two together. These were then cut in half lengthwise to create a pair of collets.







Although my welding skills are very poor the collets fitted after a bit of grinding and a 2nd set were made.

[Geoff Hastings]

Well done Greg, nice to see it progressing.