Honda305.com Forum

Because the site has been in a bit of a mess, I wasn't motivated to post details of a restoration I am doing for a friend who acquired this bike with a large quantity of Honda projects and spares.

The CYP 77 was dismantled and the parts had to be pulled together from all corners of the stockpile. I have been working on it for over six months and it is almost complete.

It started off like this once we had got most of the bits in one place.....



I put together the engine, which needed a little work, and supplied a set of period-correct carbs. The engine had suffered a little as it had been apart since 1988 so it needed checking over and cleaning.



With the engine done, we set about putting engine and frame together.



So far an interesting build for me as many of the details are not covered well in the parts manual or photographs I could find online.

G

As usual, bloody nice work G-man.

Ther Wheels for this bike are 17", rather than the 18" of the CB77 or the 16" of the CA77. Luckily we had a pair of excellent DID rims andf a pile of spokes which were the correct dimensions.

The spokes had deteriorated somewhat so I polished them up and had them all re-zinced. The nipples were yellow passivated. The hubs wre treated to a polish using a vibratory polishing vat full of ceramic beads. Although that worked really well tge little beads had a habit of lodging themselves in awkward places and were a devil to remove.



While the spokes were being re-done, I got the brake linkages together with fresh stainless rivets and assembled the brake plates.



I rather liked the satin-finish on the brake plates.



Then the spokes turned up and I was able to put some wheels together.




G

With the wheels done, it was time to assemble the suspension. I Had to locate enough parts to build a 1963 version of each end. The rear units have steel upper covers and the cast-in clevis at the bottom.

I was a little disappointed to find that the dampers had been 'dismantled' for chroming by removing the aluminum top eye abd then chroming the entire body with the internals and oil still inside. I don't like this idea as the damper rod gets a coat of cjhrome on top of the origibal layer. When this flakes off (as it will) the seals will get shredded. Time will tell......



I managed to find some top eyes from different shocks but they are a real chore to get off. A 2mm pin must be driven out before the eye can be removed but, after a bit of cursing, the job was done.



Eventually, all of the pieces came together nicely.



Front forks were next and went together nicely, until I came to attach the top clamp.



The offset was wrong and wouldn't locate on the head stem. I had to find another one which would fit correctly.



G

Gman,
I thought you had been very quiet over the past months! I had not been visiting the forum much due to the spam, so I am pleased that it has been saved.
The CYP77 looks to be coming together beautifully, thanks to your special skills and meticulous attention to detail. Very inspiring. How is the CB72 coming along? Another masterpiece in the making. Well done!
G

Gordon

Thank you for the kind comments.

The CB72 has been stalled for a while but I have got the two mufflers re-chromed and will be picking up a better seat base in the next week or so.

We're having an extension built next year which will give me some extra workshop space.

I've been sidetracked by a couple of other projects this year so I am keeping busy in 'retirement'..... :-)

The C110 is a 'rolling restoration'.....



and, the CB400F has been restored from a rusty pile of bits with a seized engine.




G

mcconnellfrance wrote: ↑

Mon Dec 02, 2019 5:43 pm

Gman,
I thought you had been very quiet over the past months! I had not been visiting the forum much due to the spam, so I am pleased that it has been saved.
The CYP77 looks to be coming together beautifully, thanks to your special skills and meticulous attention to detail. Very inspiring. How is the CB72 coming along? Another masterpiece in the making. Well done!
G

Beautiful work !
All the best,