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Introduction on Honda Tools w/photos

 
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Kirk
honda305.com Member


Joined: 08 Jul 2007
Posts: 71
Location: Portland Oregon

PostPosted: Sun Mar 13, 2011 10:54 pm    Post subject: Introduction on Honda Tools w/photos Reply with quote

This project began for me due to all the tool kits being sold on eBay and my search for a correct one for my cb77 project. After emails with 48 lesco on the 305 forum it turns out he was also working on the same project and was kind enough to supply the information he had already collected. I have expanded my research beyond the cb77 kit and I would like to receive criticism and feedback on the information provided. I have just ordered everything that is still available from Honda and when it arrives I will show a post and any differences. I have also emailed Kowa to try to attain some information on tool casting die marks such as the A and RK in a circle on what I believe to be early tools and the RK only tools. I believe the switch to RK only Marked tools was in 1973 and the black handled screwdriver was introduced in 1974.



Rk Casting mark believed to be after 1973




A Casting mark believed to be from early tools


Just a little history on the introduction on the tool manufacturer of Honda tools, Kowa Seiki.


November, 1956

Contract Signed with HONDA MOTOR CO.LTD for Designing, Developing, Manufacturing, and Selling Special Tools.


July, 1961

Contract Signed with HONDA MOTOR CO.LTD for Manufacturing and Selling In-car Tools.


http://www.kowa-seiki.co.jp/english_site/history.htm




Double Head Spanners


Every tool kit has two open-end wrenches for common hex nuts and bolts. These were referred to in the British sense as "double head spanners" in most descriptions. During 305 production in the mid-sixties, Honda abandoned the old Japanese Industrial Standard (J.I.S.) in favor of the Modified J.I.S. (I.S.O.) standard. This caused a reduction in the width between flats for all hex nuts and bolts except for 6mm. It would seem that this should have affected the wrench sizes in the tool kits, but there is no reference to anything but the original 10x14 and 17x19 wrenches. It is possible that the new smaller hex size nuts and bolts were never used by the factory (the new finer thread 3, 4, and 5mm screws certainly were). Interestingly, in my CB77 owner's manual, the wrench sizes are listed in terms of the thread diameter, not the width between flats, as 6x8 and 10x12. At any rate, the two "double-head spanners" are meant for all 6, 8, 10, and 12mm nuts and bolts.





Part numbers
99001-10140 WRENCH (10X14) (OPEN END) Still available from Honda
99001-17190 WRENCH (17X19) (OPEN END) Still available from Honda



Axle Wrench


Every tool kit has a double-ended box wrench for the axle nuts, a.k.a. "axle spanner," or "ring wrench." The CB77 axle wrench is 23x26mm to match the front and rear axle nuts. The CA77 wrench is 23x32mm. The 23mm end is for both the front and rear axle nuts, and the 32mm end is for the rear axle sleeve nut. The 23mm end of these wrenches is also the ideal tool for removing the tappet covers.

Early CL77's had the same arrangement as the Dreams on the rear wheel with a large sleeve nut holding the sprocket assembly in place. The rear wheel could be removed without loosening this sleeve nut, only the 21mm axle nut had to be removed. The early CL77's used the same 21mm axle nut on the front wheel. The wrench listed in the CL77 parts fiche is 21x23mm. The big end of this wrench could also be used for the tappet covers as per the post by LM on the 305 forum. Starting with CL77 1014496, the front axle nut went to an arrangement that was captured by the front fork clamp, and didn't require an axle nut to be removed for a tire change. The rear axle went to an arrangement similar to the CB77 with a 26mm nut. These models were probably equipped with the CB77 23x26mm wrench and the small end was now used for the tappet covers as per other posters on the 305 forum. See photos




Axel wrenches from left to right first 2 are CB77 and the rest are cl72/ CL77 Notice the Logo switches direction. The second CB77 wrench fits the rear axle on my 1967 CL77 with chrome fenders.



From left to right Ca95, Unknown marked Sanki same as ca95 wrench, Ca77, Ca77.
The Ca95 wrench measures 29x23mm. The second wrench marked Sanki and is the same size as a ca95.




Possible Ca95 or ca160 wrench Notice the manufacturer is not Kowa. It is marked Sanki







There is also one more known variant, I have not seen one yet and I do not know if both ends are 29mm, this is from the Honda tools Special Catalog printed in 1969.




Pliers 150mm

every tool kit has the same set of 15cm long pliers. All pliers I have seen are marked with the HM logo, I have 5 pairs and the grips are different on couple of pairs, I do not know if this has year of manufacture significance. Part Number: 99002-15000 PLIERS (150MM not available from Honda




Tappet Adjusting Wrench
Stamped steel. Two-headed for the Super hawk and late Scramblers with dual leading-shoe brakes, and single-headed for the Dream and early Scramblers. The single-headed wrench is offset to make it easier to use a 10mm wrench on the nut. The CB parts fiche lists a "no longer available" -010 version. The wrench in the CA95, CA160, CA175, and others looks identical to the CA77 version but is 3mm and will not work. Clarification needed here


Below are the part numbers from the online fiche

CA77,CA72

89201-259-000 WRENCH, TAPPET ADJUSTING Not Available from Honda

cb77, cb72, cl72, cl77

89201-268-000 WRENCH, TAPPET ADJUSTING Not Available from Honda 4mmx6mm


Cb/CL160, CA95, CB92 and the models the wrench cross references with.
WRENCH, TAPPET ADJ. (NOT AVAILABLE) (SKU: 89201-200-000) (Supersede: 07908-KE90200) the superseded version is available from Honda
Wrench is 3mm

WRENCH, TAPPET ADJ. (NOT AVAILABLE) (SKU: 89201-200-000) (Supersede: 07908-KE90200) the superseded version is available from Honda
CA95 A MOTORCYCLE, JPN, VIN# C95-100001, CB92 A MOTORCYCLE, JPN, VIN# CB92-010001,
CA160 A MOTORCYCLE, JPN, VIN# CA160-1000001, CA175 A MOTORCYCLE, JPN, VIN# CD175-1000001
CA175K3 A MOTORCYCLE, JPN, VIN# CD175-2005045, CB160 A MOTORCYCLE, JPN, VIN# CB160-9000001
CL160 A MOTORCYCLE, JPN, VIN# CL160-1000001 CB175K3 A MOTORCYCLE, JPN, VIN# CB175-4000001
CL175 A MOTORCYCLE, JPN, VIN# CL175-1000001, CB175K4 A MOTORCYCLE, JPN, VIN# CB175-5000001,
CB175K5 A MOTORCYCLE, JPN, VIN# CB175-6000001 CL175K4 A MOTORCYCLE, JPN, VIN# CL175-5000001, CL175K5 A MOTORCYCLE, JPN, VIN# CL175-6000001
SL175 A MOTORCYCLE, JPN, VIN# SL175-1000001, SL175K1 A MOTORCYCLE, JPN, VIN# SL175-2000001






Feeler Gauge (0.1m
All of the tool kits have a 0.1mm (.004") feeler gauge to set tappet clearance.
89231-200-000 GAUGE, TAPPET CLEARANCE ADJUST Still available from Honda




Pin Spanner 37mm
CB and CL models for shock adjustment, Part number 89204-268-000” No longer available from Honda.




Be very careful buying these on eBay there are three different Honda pin spanners that look similar see photo below, the first is correct for cb72 , CB77, CL72, CL77





Screwdriver Bits and Grip

all tool kits have with three screwdriver bits and a handle or "grip." The Phillips bits are a number 2 and 3, and fit the engine case, dynamo cover, points cover, etc. exactly. The plastic grip is still available from Honda, but comes in black. The All of the bits are still available from Honda.” I believe the switch was made in 1975 due to eBay research of a year of looking at tool kit auctions, but it is not definitive.

Part numbers

99003-10000 SCREWDRIVER 1, PHILLIPS (NO.2) Still available from Honda

99003-20000 SCREWDRIVER 2, PHILLIPS (NO.3) Still available from Honda

SKU: 99003-30000 SCREWDRIVER 3, STRAIGHT SLOT Still available from Honda

SKU: 99003-50000 GRIP





Spark Plug Wrench"


What complicates the search for a correct spark plug wrench is the switch from a 10 to a 12mm spark plug thread (and corresponding switch from 16 to 18mm hex) that occurred after the 1961 model year. There are also numerous part numbers with incomplete super-session history for what I think are very similar wrenches. Basically a stamped steel socket wrench aka "box" wrench. The latest version is still available from Honda but probably looks different than the original.”


I only have one spark plug wrench and it is 18mm hex or 12mm plug. I have a box of spark plug wrenches so I would love to see yours.

plug wrench early models with 10mm thread plugs (C10HA) 16mm hex (CA, CB, CL models)

89216-259-000 89216-130-690

89216-041-010 89216-045-670

89216-001-000 99004-16170 WRENCH, BOX (P16X17) is latest (still available)

Late models with 12mm spark plug thread 18mm hex (D8HA, D6HA plugs)

89216-028-010 89216-264-000

89216-033-000 99004-18230 WRENCH, BOX (P18X23) is latest (still available)

I do not know if the cl72 used a 10mm plug and the online fiche says no, but I doubt that is true. Clarification needed here???




12mm , 18mm hex Spark plug wrench from late model cb77 or cl77 kit







C-10HA Plug from eBay auction "cowpietu" 12/8/10. Note plug says "C-10H" and tube says "C-10HA" where "A" stands for special firing end construction in NGK terminology. The “C” prefix denotes a 16mm hex which would account for a difference in spark plug wrenches. D6HS (Dream) and D8HA (Superhawk)













Lever

all tool kits, apparently for more "leverage" on the screwdriver bits. Two versions with slightly different shapes.” It shows multiple versions in the parts book but in all of my kits they are the same. Input needed here. Added note Kawasaki has a very similar one as well.
Part number 99003-40000 LEVER still available from Honda





Points File

The points file is listed in the owner's manual and parts fiche for the Dream and Scrambler. Why not the Super hawk? ” My points file is unmarked and measures 10cm long, 4.6cm length of file blade and .5cm wide.
Part Number

89235-253-000 POINTED FILE not available from Honda







Scissors

Only appearing in the CB owner's manual without a part number, this mysterious addition to the tool kit only adds to the intrigue. Thanks to 48lesco for the photos and this information. Notice the second photo and the HM mark on the scissors. Part number is 89243-253-000 Where is the tire patch?
The part number is form the C78 , CA72 Fiche form cmsnl.com.




Notice the HM mark on the scissors.








CA72, C78 Parts book






23. 89243-253-000 SCISSORS From Serial#: C77-10001

24. 89236-253-000 FIT PATCHING OUT From Serial#: C77-10001








Tire Lever

Tire levers (2) appear in the CB model's parts fiche but not the owner's manual. A single tire lever appears in the export CA72/77 tool fiche on CMSNL. I received a pair of tire levers in a Honda dream bag with a points file; I have also seen these same tire irons in early Yamaha tool kits on eBay. They are unmarked and do not have an HM mark. They measure 182mm the online fiche says they are still available part number is 89241-253-000 LEVER, TIRE Use from Frame SN 0110001 to 0210300







Fuses and Cotter Pins
These fuses and cotter pins came in my cl77 tool kit, they were sealed in the package and I have yet to touch the restoration, so I do not know if the fuse size is correct or if they are comparable to the ones in the CA77 dream kit.








Tool Bag
The tool bag for the CB and CL models share the same part number. The CA has a different one. I have an original tool bag from a 1964 CB77 that is a green canvas. Others I've seen are black or blue or black and blue vinyl. The part number of the CA160 and CA95 is the same as the CA77/72.


Ca77, Ca72, Ca95, CB92, and CA160 Part number 89101-200-000






CB160, CL160, CL175 Bag part number 89101-216-000







Late model CB77/ CL77 part number 89101-268-000










Early Model 48Lesco’s Canvas Bag 1964 Early Cb77 ???











Variant Bags and wrenches



Reproduction Bag from Japan, believed to be from an early model 1961 cb









Possible Late Version Of dream Bag in Black from an EBay Auction,

ca95 page for blue version of bag







There is one more bag not included and that is for the 1960’s CB450 it looks very similar except for a split in the top of the fold over.

The early cb450 also shares the 37mm pin spanner





Variant 9mm wrenches from CB160 Etc.




I have seen the two on the right as variations for replacements of the original 9mm wrench in late tool kits. See the Ca95 tool page for the eBay auction kit.

_________________
2-1966 CB77 Projects
1965 CB77 Partsbike
1967 scrambler pile of parts
1972 Cb350
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e3steve
h305 Moderator


Joined: 31 Oct 2003
Posts: 2564
Location: Mallorca, Spain & Warsash, UK

PostPosted: Mon Mar 14, 2011 1:11 am    Post subject: Reply with quote

A fascinating and thoughtful series of posts; nice one, Kirk! Thanks for taking the time to do so.
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Kirk
honda305.com Member


Joined: 08 Jul 2007
Posts: 71
Location: Portland Oregon

PostPosted: Tue Mar 15, 2011 4:56 pm    Post subject: Reply with quote

Thanks Steve 48Lesco contributed quite a bit on this and I appreciate his help as this is a collaborative effort to identify these kits.

Thanks,

Kirk

_________________
2-1966 CB77 Projects
1965 CB77 Partsbike
1967 scrambler pile of parts
1972 Cb350
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jensen
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Joined: 12 Feb 2008
Posts: 1143
Location: netherlands, huizen

PostPosted: Wed Mar 16, 2011 2:03 am    Post subject: Reply with quote

Hi Kirk,

Thanks for your detailed information on the tool kits. I know it will be very helpful for those who are into detail about their tool kits (like me). Really appreciated,

Jensen

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Hoosier Tom
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Joined: 15 Aug 2008
Posts: 814
Location: Logansport, IN

PostPosted: Wed Mar 16, 2011 10:15 pm    Post subject: Reply with quote

Here's front and back photos of my tire patch.

HT
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Kirk
honda305.com Member


Joined: 08 Jul 2007
Posts: 71
Location: Portland Oregon

PostPosted: Thu Mar 17, 2011 7:11 pm    Post subject: Tire Patch Reply with quote

That is pretty cool looking, can I get measurements of the outside of the bag Please ?
Tom did the tire patch come from a Dream Kit or a CB77 kit?

Thanks,

Kirk

_________________
2-1966 CB77 Projects
1965 CB77 Partsbike
1967 scrambler pile of parts
1972 Cb350
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alan curtis
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Joined: 23 Sep 2008
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PostPosted: Mon Dec 30, 2013 4:02 pm    Post subject: tools Reply with quote

this is a great post, lots of usefull info. cheers.
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