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1963 CYP77

Want to keep a Restoration Log? Post it here! You can include photos. Suggested format: One Restoration per Thread; then keep adding your updates to the same thread...

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G-Man
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Re: 1963 CYP77

Post by G-Man » Tue Dec 03, 2019 2:20 pm

With wheels & suspension built, it was time to put the project together and get it up on its wheels. The rear tyre is a genuine NOS tyre which was in Honda packaging with a -282- model code. The front has also been in storage for many years but not a Honda part.

The wiring harness is a genuine NOS part for the CYP77 as is the ignition switch. These were stored in Honda bags dated 1988!

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The fenders are also unusual to the CYP77 as it is fitted with 17" wheels rather than teh 18" of the SuperHawk.

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The rear also has the bumper bar which holds the little box that's fitted behind the single seat. Strangely, Honda kept the 1961-style rear light on these bikes when the other models had moved on to the square type. I had to do a little work on this one to get a presentable outcome.

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It looks a strange 'dumpy' little bike when it finally stands on its own wheels.

Image

G
'60 C77 '60 C72 '62 C72 Dream '63 CL72
'61 CB72 '64 CB77 '65 CB160
'66 Matchless 350 '67 CL77
'67 S90 '77 CB400F

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G-Man
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Re: 1963 CYP77

Post by G-Man » Tue Dec 03, 2019 2:34 pm

Thankyou!

G
OldTwinRuns wrote:
Tue Dec 03, 2019 2:17 pm
Beautiful work !
All the best,
'60 C77 '60 C72 '62 C72 Dream '63 CL72
'61 CB72 '64 CB77 '65 CB160
'66 Matchless 350 '67 CL77
'67 S90 '77 CB400F

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G-Man
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Re: 1963 CYP77

Post by G-Man » Tue Dec 03, 2019 2:56 pm

Although the bike looks pretty complete, there are still plenty of jobs to do. For a start, we only had one front indicator (NOS) and one rear indicator bracket (rusty).

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I did find three more indicator bodies in need of work but I could not find anymore brackets. The challenge was on. I had to copy the two we had, in reverse, and restore the other bodies.

With a couple of different thickness of mild steel plate, I made templates of the existing parts, reversed them and cut, bent and welded a pair of 'replica' brackets. Once they were made I got them chrome plated.

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This was a pleasing job as I think my brackets are at least as good as the genuine Honda parts. Just in case you can't tell, mine ar ethe lower pair....:-)

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The bodies got re-furbished with a freshen-up of the lenses and screws, topped off with a coat of color-matched off-white paint.

Image

G
'60 C77 '60 C72 '62 C72 Dream '63 CL72
'61 CB72 '64 CB77 '65 CB160
'66 Matchless 350 '67 CL77
'67 S90 '77 CB400F

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G-Man
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Re: 1963 CYP77

Post by G-Man » Tue Dec 03, 2019 3:07 pm

I had been putting off the refurbishment of the speedometer as the bezel had been damaged. Luckily it is stainless steel so it just needed straightening (if you can say that about a circular part).....

Using a low melting-point alloy, known as 'press alloy' in the UK, I took an impression of both sides of a good part of the bezel.

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This was used to make a two part press tool which I could use to re-form the bent area.

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This worked really well, using just my bench vise, and I was able to make the bezel round and smooth again.

For a couple of pounds I managed to get the local glass specialist to cut me a new glass in 2mm thick material. They achieved, in a matter of minutes, what would have taken me all day!

Image

G
'60 C77 '60 C72 '62 C72 Dream '63 CL72
'61 CB72 '64 CB77 '65 CB160
'66 Matchless 350 '67 CL77
'67 S90 '77 CB400F

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G-Man
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Joined: Wed Mar 25, 2009 5:17 pm
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Re: 1963 CYP77

Post by G-Man » Tue Dec 03, 2019 3:18 pm

On my last vist, I was able to get the controls fitted, wiring hooked up in most places and various other details fixed.

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I had to make a list so that my next visit is nearly the last and I hope to have the bike running soon. There are quite a lot of parts to buy/modify/make to get the thing finished. For instance, th estarter solenoid is re-located from the bottom o=f the toolboz to th efront to clear the siren drive. In their wisdom, Honda changed the bolt-spacing of the solenoid. Go figure!

Also I cannot find pictures, or details for the coil/condenser bracket so I have had to improvise using, what I think is, a Dream part.

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The mounting tabs were re-located and some nuts welded on to mount the condenser.

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The main stumbling block at the moment is that the CYP 77 is unique in the Honda police bike field as the siren rotates clockwise.

From the CB450P onwards the others rotate counter-clockwise. I need to find a CYP 77 specific siren or reverse the direction of the CB450 one that we have.

Recently, I had a trip to the David Silver Collection. The CYP77 on the left here is the younger (1964 vs 1962) sister of our own bike....

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G
'60 C77 '60 C72 '62 C72 Dream '63 CL72
'61 CB72 '64 CB77 '65 CB160
'66 Matchless 350 '67 CL77
'67 S90 '77 CB400F

mcconnellfrance
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Location: Ayr, Scotland

Re: 1963 CYP77

Post by mcconnellfrance » Wed Dec 04, 2019 2:17 pm

Graham,

You have been busy! A pal of mine had a C110 when we were 16 year old kids. Seeing yours brings back some memories of haring around at 50mph! I had a red S65 with the high exhaust which seemed sporty at the time. The CB400F looks brilliant too. Just having a hip done in hospital and hoping that I can get back to riding my CB77 soon.

All the best,

Gordon

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G-Man
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Re: 1963 CYP77

Post by G-Man » Wed Dec 04, 2019 5:04 pm

Gordon

Thanks again for the kind words.

Good luck with your recovery. I hope you get back on the road in the New Year.

G
mcconnellfrance wrote:
Wed Dec 04, 2019 2:17 pm
Graham,

You have been busy! A pal of mine had a C110 when we were 16 year old kids. Seeing yours brings back some memories of haring around at 50mph! I had a red S65 with the high exhaust which seemed sporty at the time. The CB400F looks brilliant too. Just having a hip done in hospital and hoping that I can get back to riding my CB77 soon.

All the best,

Gordon
'60 C77 '60 C72 '62 C72 Dream '63 CL72
'61 CB72 '64 CB77 '65 CB160
'66 Matchless 350 '67 CL77
'67 S90 '77 CB400F

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