I'm puzzled by this too. However, I don't think it has anything to do with the cam chain tensioner. I disassembled one and didn't see anything like that. The tensioner is easily removed without removing anything else. If that was part of it then it should be obvious both in appearance and smoothness ...

I had a similar problem and solved it by going to a store that sells body shop supplies, including paint. They were able to match a colour very well and fill spray cans with the necessary paint. It was expensive so I built the film with two coats of off the shelf grey primer and two of colour. There ...

Your guess is correct.

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 ...

The CB77 spec is

Inner spring length 37.54 mm
Outer spring length 43.36 mm

You mentioned installed length but that will indicate nothing about the condition of the spring. The above lengths are free lengths. I believe that the specs are identical with the CL77.

kaniyrret wrote: ↑

Wed Nov 05, 2025 8:02 pm

Cool project, are you sure it's 64mm? That's like the S12 305 piston size. Bill Silver in the US just had several sets for sale.

What do you mean by S12? I've never heard of it.

I've rebuilt a few CB77 relays but have no experience with CA77s but I suspect they are either similar or identical. Here are a few comments.

First, is your battery in good condition and charged? This is a requirement for the starter to work. If you need to, a 12V car battery or portable jumper ...