Next Victim 1966 CL77 Gentleman's Scrambler

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flyin900
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Next Victim 1966 CL77 Gentleman's Scrambler

#1

Post by flyin900 »

So through a local CVMG member and friend I was connected to another local CVMG member who was looking to sell his 1966 CL77 Honda, as it needs some attention. The motor is free, yet the kick starter assembly doesn't engage now and is seized, where it always did previously.
So with the complete time capsule of a bike, I plan to do another high quality restoration. These bike do have a following and collector interest, which is important too. The parts and restoration costs will easily match the bikes purchase cost again.
I have been too spoiled in the past with good buys on bikes and very reasonable restoration costs previously by doing it all myself.
I really like this early Honda style and it has been on my radar, in kind of a back burner sense. If one came along in a mostly complete form which this one is; I would be interested. So the opportunity arrived and this time I took lots of before pictures with it already in my garage. The gas tank and seat are in great condition too.


POSSIBLE FINISHED COLOUR SCHEME.
POSSIBLE FINISHED COLOUR SCHEME.
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ANOTHER COLOUR OPTION
ANOTHER COLOUR OPTION
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Last edited by flyin900 on Tue Dec 14, 2021 12:28 pm, edited 2 times in total.
Current Bikes:

1966 CL77 - Honda 305cc - Dual purpose - "Gentleman's Scrambler" was a period moniker.
1967 CL175K0 - Low production number with #802 engine serial- winter 2019/2020 full restoration.
1972 CB350F - Baby Four with low mileage - Cosmetic refresh to the next level 2021/2022.
1978 CB550K - Very original bike with only 7499 Km. from new - light cleanup and refresh done.
1983 CB1100F - Canadian model - DOHC Supersport in pristine low kilometre condition from new.
1984 GL1200 - Standard model in showroom condition - two owner bike from new.
1984 CX650E - Restored summer 2017 - a rare Eurosport model - excellent one owner bike.
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flyin900
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#2

Post by flyin900 »

The bike has lots of patina, yet is very complete. It is only missing a main stand which is a easy and reasonable used parts purchase. I will be going through the engine entirely, so I will work on lots of pictures since the engineering is quite interesting.
No shell bearing on the crank or conn rods, just high quality ball and roller cage bearing designs on critical parts; good for 100K miles.


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Current Bikes:

1966 CL77 - Honda 305cc - Dual purpose - "Gentleman's Scrambler" was a period moniker.
1967 CL175K0 - Low production number with #802 engine serial- winter 2019/2020 full restoration.
1972 CB350F - Baby Four with low mileage - Cosmetic refresh to the next level 2021/2022.
1978 CB550K - Very original bike with only 7499 Km. from new - light cleanup and refresh done.
1983 CB1100F - Canadian model - DOHC Supersport in pristine low kilometre condition from new.
1984 GL1200 - Standard model in showroom condition - two owner bike from new.
1984 CX650E - Restored summer 2017 - a rare Eurosport model - excellent one owner bike.
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flyin900
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Location: Canada

Re: Next Victim 1966 CL77 Gentleman's Scrambler

#3

Post by flyin900 »

flyin900 wrote: Mon Dec 13, 2021 8:36 pm The bike has lots of patina, yet is very complete. It is only missing a main stand which is a easy and reasonable used parts purchase. I will be going through the engine entirely, so I will work on lots of pictures since the engineering is quite interesting.
No shell bearing on the crank or conn rods, just high quality ball and roller cage bearing designs on critical parts; good for 100K miles.



P1070796.JPGP1070799.JPGP1070800.JPGP1070802.JPGP1070831.JPG
Current Bikes:

1966 CL77 - Honda 305cc - Dual purpose - "Gentleman's Scrambler" was a period moniker.
1967 CL175K0 - Low production number with #802 engine serial- winter 2019/2020 full restoration.
1972 CB350F - Baby Four with low mileage - Cosmetic refresh to the next level 2021/2022.
1978 CB550K - Very original bike with only 7499 Km. from new - light cleanup and refresh done.
1983 CB1100F - Canadian model - DOHC Supersport in pristine low kilometre condition from new.
1984 GL1200 - Standard model in showroom condition - two owner bike from new.
1984 CX650E - Restored summer 2017 - a rare Eurosport model - excellent one owner bike.
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ritalz
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#4

Post by ritalz »

I'll be watching. My first real street bike was a 66 CL77. One winter I bored it out and put in pistons from a 350, a bigger cam and 350 carbs. Still could not beat my friends CL350. Fun bike.
Al

2003 Goldwing Daily Rider
1975 Goldwing 'Max'
1984 Goldwing New Bagger Project
1976 Goldwing 'Grocery Getter' Sold
1985 Goldwing Interstate 'NCC-1985' sold
1981 Silverwing Sold
1982 Goldeing Project Sold
1981 Goldwing Parted Out
1983 Goldwing Project Sold
1973 CB500F Long Gone
1966 CL77 First Street Bike
http://www.ngwclub.com/gallery3/index.p ... ans/ritalz
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Whiskerfish
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#5

Post by Whiskerfish »

Very worthy restoration bike!! I never owned one but I always loved the look.
"Agreement is not a requirement for Respect" CDR Michael Smith USN (Ret) 2017
"The book is wrong, this whole Conclusion is Fallacious" River Tam
2008 GL1800 IIIA "TH3DOG"
1975/6/7/8/9 Arthur Fulmer Dressed Road bike
1975 Naked Noisy and Nasty in town bike
and a whole garage full of possibilities!!

Psst. oh and by the way CHANGE YOUR BELTS!!!!
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Lucien Harpress
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#6

Post by Lucien Harpress »

I've been having a hankering for a 60s Honda for a little while now. I think I'll live vicariously through this thread for a bit before deciding to pull the trigger or not ..
1997 Valkyrie- Light Cutomization, but Too Busy Riding
1980 KZ1300- Bike's Haunted
1976 GL1000 (Yellow)- It Runs (Poorly) and Doesn't Leak (Mostly)
1974 Velosolex 3800- Better Than Walking
1972 CB750- Broke the Chain And Ate the Motor
1969 CT90- The Most Fun You Can Have on 90ccs.
1965 CA77 Dream- Needs a Full Teardown, but Complete

All advice I give is only valid until an expert corrects me.
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flyin900
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#7

Post by flyin900 »

So thanks to Sandy R here in town I was able to get the bike home quickly to take advantage of this warmer for December few days recently. Nothing but blue skies yesterday and today.

Thank you Sandy for the quick loan of the mini trailer and vehicle to get it here and two great pictures still on the trailer.

1966 CL77 - 305cc
1966 CL77 - 305cc
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1966 CL77 - 305cc
1966 CL77 - 305cc
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Current Bikes:

1966 CL77 - Honda 305cc - Dual purpose - "Gentleman's Scrambler" was a period moniker.
1967 CL175K0 - Low production number with #802 engine serial- winter 2019/2020 full restoration.
1972 CB350F - Baby Four with low mileage - Cosmetic refresh to the next level 2021/2022.
1978 CB550K - Very original bike with only 7499 Km. from new - light cleanup and refresh done.
1983 CB1100F - Canadian model - DOHC Supersport in pristine low kilometre condition from new.
1984 GL1200 - Standard model in showroom condition - two owner bike from new.
1984 CX650E - Restored summer 2017 - a rare Eurosport model - excellent one owner bike.
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flyin900
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Teardown today

#8

Post by flyin900 »

Here are a few of the get it apart pictures. I have to keep telling myself this is the easy part of the job. Pictures pictures pictures is my motto. Because I don't remember what I had for breakfast, so I can't be sure 3 months from now. :-D

A nice discovery is that someone put an aftermarket electronic points replacement set up in the bike. I have the electronic box too. I did get a number of spares, including the original points and plate and 3 sets of proper scrambler handle bars. Carb parts and a .25 oversize piston for a CR125? lol.

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Current Bikes:

1966 CL77 - Honda 305cc - Dual purpose - "Gentleman's Scrambler" was a period moniker.
1967 CL175K0 - Low production number with #802 engine serial- winter 2019/2020 full restoration.
1972 CB350F - Baby Four with low mileage - Cosmetic refresh to the next level 2021/2022.
1978 CB550K - Very original bike with only 7499 Km. from new - light cleanup and refresh done.
1983 CB1100F - Canadian model - DOHC Supersport in pristine low kilometre condition from new.
1984 GL1200 - Standard model in showroom condition - two owner bike from new.
1984 CX650E - Restored summer 2017 - a rare Eurosport model - excellent one owner bike.
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dontwantapickle
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#9

Post by dontwantapickle »

Not only do you have excellent restoration skills....
It also appears that your ability to find good condition restorable motorcycles is unmatched.
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flyin900
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Location: Canada

Re: Next Victim 1966 CL77 Gentleman's Scrambler

#10

Post by flyin900 »

Thank you.

I have a keen interest in earlier Honda models, so I am always looking on local sales venues for specific bikes. Membership in CVMG has been a great help too. I have gravitated to the earlier Honda models these past few years, with the 60's models a favorite now.

This bike was a fortunate circumstance, as they are fewer 1960's CB or CL series for sale around here locally.

So a little more of the frame and wheels removed, so I am down to the motor removal now. I will wait for some assistance here as the removal requires two old guys these days, with a third on standby if needed. :orange


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OIL DIPSTICK" CHIMNEY PIPE"
OIL DIPSTICK" CHIMNEY PIPE"
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Current Bikes:

1966 CL77 - Honda 305cc - Dual purpose - "Gentleman's Scrambler" was a period moniker.
1967 CL175K0 - Low production number with #802 engine serial- winter 2019/2020 full restoration.
1972 CB350F - Baby Four with low mileage - Cosmetic refresh to the next level 2021/2022.
1978 CB550K - Very original bike with only 7499 Km. from new - light cleanup and refresh done.
1983 CB1100F - Canadian model - DOHC Supersport in pristine low kilometre condition from new.
1984 GL1200 - Standard model in showroom condition - two owner bike from new.
1984 CX650E - Restored summer 2017 - a rare Eurosport model - excellent one owner bike.
User avatar
flyin900
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Posts: 1489
Joined: Sun Jan 10, 2010 3:50 pm
Location: Canada

Re: Next Victim 1966 CL77 Gentleman's Scrambler

#11

Post by flyin900 »

Interesting few days which allowed me to get much further along, yet it took me most of yesterday to get the head apart with the cams bearings and totally different design.

The early Goldwings have nothing on the complexity of that head with those parts really stuck together. I was afraid to break anything. There are two small cam halves with a central cam gear that these two cam halves interlock into and the whole thing which rides on four, I mean four 6004 roller bearings.

After lots of questions I finally got it apart with two bearings questionable.

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Last edited by flyin900 on Sun Dec 19, 2021 5:44 pm, edited 1 time in total.
Current Bikes:

1966 CL77 - Honda 305cc - Dual purpose - "Gentleman's Scrambler" was a period moniker.
1967 CL175K0 - Low production number with #802 engine serial- winter 2019/2020 full restoration.
1972 CB350F - Baby Four with low mileage - Cosmetic refresh to the next level 2021/2022.
1978 CB550K - Very original bike with only 7499 Km. from new - light cleanup and refresh done.
1983 CB1100F - Canadian model - DOHC Supersport in pristine low kilometre condition from new.
1984 GL1200 - Standard model in showroom condition - two owner bike from new.
1984 CX650E - Restored summer 2017 - a rare Eurosport model - excellent one owner bike.
User avatar
flyin900
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Posts: 1489
Joined: Sun Jan 10, 2010 3:50 pm
Location: Canada

Re: Next Victim 1966 CL77 Gentleman's Scrambler

#12

Post by flyin900 »

The motor came out quite easily when I loosened all the bolts and used the same strategy as the CB350F of laying the sub frame and motor on it's side and maneuvering the frame off the sideways motor.

Stressed the old back when picking that up onto the motorcycle lift, :( yet once on there it came apart quickly with the heads, barrels and clutch assy. I split the cases and cleaned out all the nasty sludge, as this one was not maintained oil change wise, or the DINO oil was pretty basic back then.

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Current Bikes:

1966 CL77 - Honda 305cc - Dual purpose - "Gentleman's Scrambler" was a period moniker.
1967 CL175K0 - Low production number with #802 engine serial- winter 2019/2020 full restoration.
1972 CB350F - Baby Four with low mileage - Cosmetic refresh to the next level 2021/2022.
1978 CB550K - Very original bike with only 7499 Km. from new - light cleanup and refresh done.
1983 CB1100F - Canadian model - DOHC Supersport in pristine low kilometre condition from new.
1984 GL1200 - Standard model in showroom condition - two owner bike from new.
1984 CX650E - Restored summer 2017 - a rare Eurosport model - excellent one owner bike.
User avatar
flyin900
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Location: Canada

Re: Next Victim 1966 CL77 Gentleman's Scrambler

#13

Post by flyin900 »

I discovered the lower case half has a missing chunk that is patched and glued which is coming apart. I reused the patch piece as it fit well and used the Tech Steel metal epoxy compound to fill and rebuild the missing engine case fins.
I have used Tech Steel on many repairs with excellent success as it is strong, chemical resistant and good for 500F temp wise.

My plan is to roughly fill and build the fins up and Dremel drum sand the area and refill any low spots and shape the finished repair. I will build the next Tech Steel level tomorrow and finish it later in the day, as 15 mins to rock hard working time and 1 hr for a full cure.



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Current Bikes:

1966 CL77 - Honda 305cc - Dual purpose - "Gentleman's Scrambler" was a period moniker.
1967 CL175K0 - Low production number with #802 engine serial- winter 2019/2020 full restoration.
1972 CB350F - Baby Four with low mileage - Cosmetic refresh to the next level 2021/2022.
1978 CB550K - Very original bike with only 7499 Km. from new - light cleanup and refresh done.
1983 CB1100F - Canadian model - DOHC Supersport in pristine low kilometre condition from new.
1984 GL1200 - Standard model in showroom condition - two owner bike from new.
1984 CX650E - Restored summer 2017 - a rare Eurosport model - excellent one owner bike.
User avatar
flyin900
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Posts: 1489
Joined: Sun Jan 10, 2010 3:50 pm
Location: Canada

Re: Next Victim 1966 CL77 Gentleman's Scrambler

#14

Post by flyin900 »

Some further improvement on the fin rebuilding and general repair of this damaged case area. I just completed another Tech Steel fill of this repair and will be shaping and sanding the final piece tomorrow.

Here are the tools I used for the shaping and sanding procedure and I have under 2hrs total into it so far in repair time.



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Current Bikes:

1966 CL77 - Honda 305cc - Dual purpose - "Gentleman's Scrambler" was a period moniker.
1967 CL175K0 - Low production number with #802 engine serial- winter 2019/2020 full restoration.
1972 CB350F - Baby Four with low mileage - Cosmetic refresh to the next level 2021/2022.
1978 CB550K - Very original bike with only 7499 Km. from new - light cleanup and refresh done.
1983 CB1100F - Canadian model - DOHC Supersport in pristine low kilometre condition from new.
1984 GL1200 - Standard model in showroom condition - two owner bike from new.
1984 CX650E - Restored summer 2017 - a rare Eurosport model - excellent one owner bike.
User avatar
flyin900
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Posts: 1489
Joined: Sun Jan 10, 2010 3:50 pm
Location: Canada

Re: Next Victim 1966 CL77 Gentleman's Scrambler

#15

Post by flyin900 »

Finished item with about 2.5 HRS of work and a great improvement in both the strength and cosmetic look of the lower case now. I am happy with the repair and it was not a complicated, time consuming, or requiring specialized tools to complete repair.


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Last edited by flyin900 on Mon Dec 27, 2021 7:00 pm, edited 1 time in total.
Current Bikes:

1966 CL77 - Honda 305cc - Dual purpose - "Gentleman's Scrambler" was a period moniker.
1967 CL175K0 - Low production number with #802 engine serial- winter 2019/2020 full restoration.
1972 CB350F - Baby Four with low mileage - Cosmetic refresh to the next level 2021/2022.
1978 CB550K - Very original bike with only 7499 Km. from new - light cleanup and refresh done.
1983 CB1100F - Canadian model - DOHC Supersport in pristine low kilometre condition from new.
1984 GL1200 - Standard model in showroom condition - two owner bike from new.
1984 CX650E - Restored summer 2017 - a rare Eurosport model - excellent one owner bike.
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