CA77 Dream Restoration Questions

[morgataz]

2 questions:

1) Is a factory service manual for a CA77 available anywhere on-line for free? I've seen some for sale on E-bay from $60-80. Trying to restore my Fathers 68 Dream, service manual would be helpful.

2) Does anyone know where I an get clutch plates; either for purchase or custom-made to CA77 specs? The clutch is slipping in & out pretty badly. Oil is flecked with metal fragments. so think clutch plates have begun to decompose. Bike has sat for about 12 years without being started/ridden.

[Nick]

There are plenty of generic Honda 305 manuals out there for cheap as new, and very cheap used.

A search for vintage Honda parts will show many suppliers of old Honda parts. There are even some on this site!

[G-Man]

Google Scrambler Cycle, who is a Forum member called Hahnda. You might find both items on his site.

Why do you think the metal particles are from your clutch?

G

2 questions:

1) Is a factory service manual for a CA77 available anywhere on-line for free? I've seen some for sale on E-bay from $60-80. Trying to restore my Fathers 68 Dream, service manual would be helpful.

2) Does anyone know where I an get clutch plates; either for purchase or custom-made to CA77 specs? The clutch is slipping in & out pretty badly. Oil is flecked with metal fragments. so think clutch plates have begun to decompose. Bike has sat for about 12 years without being started/ridden.

[cadman]

Clutch plates are fairly easy to find - here's an ebay link - https://www.ebay.com/b/Motorcycle-Clutc ... n_20993449 also one from Classic Cycle parts - https://classiccycleparts.com/index.php ... 0-305.html

Metal anywhere in the engine is a problem. I would drain the oil - I would assume that the oil is old and terrible so I usually add something - gas, kerosene, paint thinner - to thin it a bit before draining. Drain into a clean shallow pan - run a magnet through it to see what you find. Anything steel will stick aluminum will not. Then drain though a coffee filter and see what you get.

The clutch is in part of the engine oil system so the particles could be from anywhere. When you get ready to start the engine I would fill it with a lite weight oil and run it a few minutes and then drain to try and capture as may metal particles as you can.

[G-Man]

Google Scrambler Cycle, who is a Forum member called Hahnda. You might find both items on his site.

Why do you think the metal particles are from your clutch?

G

2 questions:

1) Is a factory service manual for a CA77 available anywhere on-line for free? I've seen some for sale on E-bay from $60-80. Trying to restore my Fathers 68 Dream, service manual would be helpful.

2) Does anyone know where I an get clutch plates; either for purchase or custom-made to CA77 specs? The clutch is slipping in & out pretty badly. Oil is flecked with metal fragments. so think clutch plates have begun to decompose. Bike has sat for about 12 years without being started/ridden.

[LOUD MOUSE]

Knowing the part number of the plate is very important when it comes to clutch plates.
All the numbers I'll show will have aluminum cores and Black with Cork surfaces
Last used in 1967 - 22201-268-000 3.6MX13.3M used the steel plates with the 7 cut outs in the center hole
Next was subbed to - 22201-268-020 SAME
Next was subbed to - 22201-268-020 3.5MX13M Same numbers with different dimensions and smaller SQUARES
Next was subbed to - 22201-MK2-000 2.9MX11.3M SMALL SQUARES
If you use the MK2 you will need to add one more FD and one more Steel.
Chances are the DREAM you have may still have the plastic/? used on all the early engines of the C/CA/CB/CL 72/77 issues. ...................lm

Clutch plates are fairly easy to find - here's an ebay link - https://www.ebay.com/b/Motorcycle-Clutc ... n_20993449 also one from Classic Cycle parts - https://classiccycleparts.com/index.php ... 0-305.html

Metal anywhere in the engine is a problem. I would drain the oil - I would assume that the oil is old and terrible so I usually add something - gas, kerosene, paint thinner - to thin it a bit before draining. Drain into a clean shallow pan - run a magnet through it to see what you find. Anything steel will stick aluminum will not. Then drain though a coffee filter and see what you get.

The clutch is in part of the engine oil system so the particles could be from anywhere. When you get ready to start the engine I would fill it with a lite weight oil and run it a few minutes and then drain to try and capture as may metal particles as you can.