1966 Honda Scrambler Restore---JS

[sarals]

...and smiling, I'll bet! Great work!

[jsmith1107]

Cripes sake, when I was tightening the one that broke and I heard that snap, I swear my whole stomach dropped. I didn't even know they were just screwed into the upper case, I thought they were cast in there so who did I call right away asking about possibly welding it together? LM of course. Once he told me it was only screwed into the upper case I was relieved a little but still had to take the dang thing into pieces again---and that made me sick actually. I pulled all of it apart and what did I have but maybe a half inch to work with tops. Then, to top it all off, didn't have the right vice grips for the job so had to take a quick run to the hardware store, got back, clamped it on and it wouldn't budge. The only thing I could think was, please don't break off again so I have to drill it out and extract it. Low and behold after clamping and reclamping I heard a snap and it busted loose. Whew, it was the biggest relief ever!! Now, all I had to do was get one out of a case I actually bought a while ago because I thought I would need it because of the crack in mine that I fixed with JB Weld. It shoudl be no problem getting that long one out right? Yeah, not so much, it wouldn't budge so I heated it up and tried and tried and tried for about 6 times and then all of a sudden it busted loose. Finally!! All back together again and I will tel you this, when I had to tighten that top again, I was SO worried about even doing it for fear of another one busting but I did. I have only been putting 14 lbs of torque on them so not sure why it busted, must have been soft from someone else cranking it too tight or something. I know, this is a long story but finally, I am back to where I was about a day ago. HA

[sarals]

These old machines like to toss out wrinkles, don't they? I've found through working on mine that patience and flexibility are a MUST, because things you didn't expect are going to crop up, and you're going to make mistakes (especially me). I'm glad your stud adventure came out well!

[jsmith1107]

yeah, and unfortunately I lack the patience some times. I am learning though because everything is 50 years old and needs to be treated delicately for the most part.

[sarals]

Some parts do need a soft touch, yes - but some are pretty tough. What has surprised me, really, is that the age of the bike doesn't mean a heck of a lot, other than it's built quite a bit "sturdier" than newer bikes are. There's not much in the way of "weight saving". Some of the materials don't seem to be quite as tough as newer stuff, but all in all, it's built pretty well. I've come to think that the Honda's from that era are sort of a dichotomy. The major parts seem to be intended to last virtually forever, but then there are those little critical parts (like the 19mm bushing in the transmission) that last maybe 18 to 20K miles and then are worn out - which dictate that the bike needs to be overhauled relatively often - sort of like an airplane, I suppose. It seems to me that if someone pays attention to and takes care of their CL, CB, CA it WILL last a lifetime (or longer).

Sorry for the rant, I get sidetracked!! Thinking out loud. ;)

[G-Man]

Sara

Thant's an interesting viewpoint. At the time of making these Hondas they were, I think, rushing them to market and as with any engineering project each part was at a slightly different state of development.

In particular they were not paying a lot of attention to production engineering. If you look at a front fork tube from my CB400, just ten years later, it is just pretty much a plain tube of a single diameter. In contrast, the SuperHawk fork tube has around three different diameters, holes, circlip grooves, tapers - the lot. That makes it harder and more costly to make.

Those engines contain 4 different chains and the gearbox is just horrible, when compared with later designs. The whole 14mm bush, mainshaft, kickstart arrangement is just nasty.

But, as you say, some parts are superbly robust. Most of the engine and the wheels are a delight. They were trying to produce a thoroughly modern motorcycle. Contrary to lots of British naysayers at the time the basic structure appears to last forever.

And the dichotomy is still there. My CB77 looks like it lived at the bottom of a river and has clearly suffered abuse at the hands of the British climate. DEspite rusted engine internals, the fenders and frame are in superb order.

My basket-case 1960 Dream is in lovely condition body-wise yet was taken off the road, never to return, in around 1963, with what I guess an unrepairable engine fault. Three years usable life was hardly a bargain for such an expensive machine.

G

[jsmith1107]

Alright more progress today. I always have my sites set high to get a lot done but then for some reason, it doesn't seem like I get anywhere. This morning I spent two hours blowing a foot of snow--and it is mid to late April for crying out loud. Then, once again, had to talk to Ed and make sure something was right before I put the engine in the frame. And of course, I am glad I talked to him again---or I would be taking it apart for the umpteenth time.