Next Victim 1966 CL77 Gentleman's Scrambler

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robin1731
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#46

Post by robin1731 »

gltriker wrote: Sun Mar 20, 2022 3:52 pm
I spotted the lower end of the 1 piece connecting rods had to utilize roller bearings, too. Oh, look there, a cam chain sprocket between the 2 inboard bearings.
WOW! The CL77 crankshaft assembly is press assembled like a 2 stroke engine crankshaft assembly would be. WOW, AGAIN!

Same as Kawasaki Z1's, KZ900's and KZ1000's. Along with some others too. ;)
1976 Goldwing Super Sport
1985 Honda Elite
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1992 ZX7 Dragbike (KZ900 style motor w/NOS)
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Shadowjack
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#47

Post by Shadowjack »

The first Honda (I think) to use a plain-bearing crank was the CB750, and all other fours after that. Not sure how long they used built-up cranks in other bikes. The other manufacturers had all that two-stroke experience, so they continued for a while after that.
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#48

Post by flyin900 »

These motors in general were definitely overbuilt in many areas and still somewhat in their infancy technology wise in others. The pressed crank is definitely an area that as noted two strokes and other manufacturers used for many years.
I believe the heads are sandcast, which is something that Honda also used on the early CB750's SOHC bikes.
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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More small items done

#49

Post by flyin900 »

Parts are still coming in for the build and the weather has co-operated recently and allowed me to paint the side covers and prime a few other small parts. A little rusty on the clear coat (runs) on the side covers, so a little sanding and re shooting is in order. Next week should have two decent days if the weather man is correct, so I will shoot primer/filler on the frame and other remaining parts. I buffed both the brake plates and some of the other small aluminum engine covers.

I installed two main chains on the left side of the motor. The main primary chain was sourced from Thailand (NOS) and this chain is NLA and really scarce now ($$$). It is an oddball size #320 that no one makes anymore. The sad parts is when their gone its over for a replacement of this part. I contacted many different chain suppliers in the US and Britain and various vendors too. No one has been able to find a source to replace it to date and the major chain manufacturers don't make anything comparable.

The small oil spinner chain has gone the same route and a Thai vendor who had a NOS part wanted $200.US for that silly little 40 link chain. With lots of digging I found a US supplier of a #25 heavy duty chain that met the specs of the original, so for $30.US I got 10 feet and some spare links and a chain splitter tool. dancr



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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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Some Cloud Silver paint applied today

#50

Post by flyin900 »

Not a lot of progress, yet the weather has been pretty sketchy overall. I paint outside, either just out back of my garage or in a gazebo affair. So I need to have little wind and some decent weather above 10 C if possible.
I had my local shop mix a PPG paint close to the Honda Cloud Silver and add a little metal flake for some extra pop. Some small mistakes that will require a little sanding and touch up, which is typical with the outdoors venue. I also have the red paint for the frame and other key body bits mixed for another day.
Hopefully by mid May I can have most of the painting done and focus more on the assembly. I have received some chrome bits back with more scheduled next week.

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The rims are back so the hubs are ready to lace up again as a next project.

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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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Whiskerfish
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#51

Post by Whiskerfish »

Looks great!

Amazing how critical we can be of our own work action1 action1 action1 action1
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and a whole garage full of possibilities!!

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flyin900
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#52

Post by flyin900 »

Whiskerfish wrote: Fri Apr 22, 2022 8:02 pm Looks great!

Amazing how critical we can be of our own work action1 action1 action1 action1
Thanks Whisker... It's one of those it looks good in the pictures, yet there are some small lumps and other issues that the paint always shows.

We finally had a 20 Celsius day today, so I was able to paint the frame and all the associated bits and bobs. I chose a Ford red which is close to the correct Honda frame colour. It went well, so I also clear coated the semi dry red finish and avoided having to sand the red later if I had left it to fully cure.

Just a picture of the frame today :-D


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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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Red it is!

#53

Post by flyin900 »

So these bikes came in three flavours of frame colours. The standard black that is pretty common and a red and blue option with Cloud Silver tanks and side covers, until the last years in 1967/68. Then some additional tank colours were available.

I liked the red which seems to be a common theme on many restored versions that are out there. The blue while nice came with chrome fenders which this bike does't have being an earlier model.

So I went with red and have started to receive more parts back in chrome like the exhaust and chrome rims, so a little more painting ahead then the reassembly begins.


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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

#54

Post by flyin900 »

I had my kick starter knuckle hard chromed to upsize it for the past wear in the outer case bushing and on the knuckle itself. I unfortunately measured the bushing incorrectly with cheap calipers. So I still had too much slop where the knuckle passes through the outer case.
Yesterday I had my friend the machinist attempt to press out the old bushing from the side case with no luck. Honda uses a special process called (ALFIN) which is a cast in place assembly with that bushing in the case. So no joy and plan B is to machine out most of the old bushing in the case and fabricate a new bushing from bronze. This will match the correct new specs of the diameter on the kick starter assembly.

Case and kick starter elbow presently. New bronze bushing material on order.

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Last edited by flyin900 on Sun May 22, 2022 9:28 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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Lucien Harpress
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Re: Next Victim 1966 CL77 Gentleman's Scrambler

#55

Post by Lucien Harpress »

Looking great so far. Seeing everything laid out like that just looks SO nice.

A bit late I suppose, but going back to painting recessed lettering and whatnot- I've had very good luck with painting everything, then almost immediately wiping the raised parts with a thinner or solvent (I currently use MEK because I don't mess around). It's definitely quicker than trying to do everything by hand.

Obviously this works best on bare metal surfaces, but there are techniques to making it work on painted surfaces as well. It's great for stuff like engraved lettering on switch controls, etc.
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

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