CB77 right side engine cover

[prodigal son]

Seems there are a lot of these covers cracked in the same location. My guess is this because of incorrect timing the gears and lever when assembling? I can't seem to find any information in my shop manual or anywhere else. What is the correct assembly sequence? Thanks, Gary

[Michael Stoic]

Gary,

The right covers are sometimes cracked because of overly aggressive pedal kicking, or, possibly, someone trying to free a frozen motor. The flex can crack the cover. I may have done something like that at least once...

Mike Stoic

[Tim Allman]

Gary,

The right covers are sometimes cracked because of overly aggressive pedal kicking, or, possibly, someone trying to free a frozen motor. The flex can crack the cover. I may have done something like that at least once...

Mike Stoic

It's a bit more than that. Honda identified this problem as coming from lack of lubrication in the bushing that supports the shaft. Those grease fittings are there for a reason but they are often ignored.

It's quite possible to repair these covers as long as the damage is not too great. The crack can be welded on the inside under inert gas. If the fibre bushing has worn it can be replaced with an identical bronze one, either press fit or, more conveniently, with a looser fit held in with Locktite. All you need is a machine shop to make the bushing. My local automotive shop does stuff like this. Maybe yours will too.

One thing nice about the bronze bushing is that the friction with the shaft is fairly low even without grease. This is not a recommendation not to grease it.

Like Michael I have experience with this.