Hey All,
Long time lurker, new poster. I picked up this old cl77 from a guy for 250 bucks a few years ago. It was pretty well beat inside and out. If you are interested in the back story, which is kinda cool, then skip to the bottom and read. Unfortunately I lost the pictures of the bike when I got it.
Anyway I am in the process of rebuilding the transmission and engine, and found so much useful info on here that I thought I should contribute instead of just lurking!
Earlier this week I cracked the cases and started cleaning them up.
I attached some photos i took during disassembly. Not all of these photos are particularly relevant but also this is useful for myself as a reference for rebuilding.
BACKSTORY
Ok so back in 2010 or 2011, I can't remember, I had a habit of buying junky old hondas, fixing them in front of my house on weekends, and selling them to people at very little profit or often a loss, if my time was worth ANYTHING, lol. Anyway my house where I was doing this is right down town and people were always stopping to shoot the sht. One day a guy who goes to the church next door stopped by and asked if I wanted an old honda cl77. I actually had no idea what that was at the time, but I said I would go check it out.
When I went to his house a few weeks later, he dragged out the dirtiest, cobbled together ancient motorcycle I had seen. It was barely visible under all the dust and dirt, looked like it slept a few decades under a lumber pile. The guy was getting divorced, I learned, and had to move out, and the bike which he had owned since it was new had to go. I felt bad and offered him 250 for it, which he took.
Once I got the bike home, and started reading about it (mostly here!) I found out that pretty much all the valuable hard to get parts were missing. The og tank was swapped out with the most awful horrid tear drop thing, no exhaust, no fenders, and a bunch of other good bits missing. I was kinda feeling down about it and let the project sit in the corner.
Several weeks later, I came home and found some boxes on the front porch full of most of the parts that were missing, although they were pretty tattered. A little bonus was a bunch of OEM honda seals and cables complete with receipts from before I was walking. Clearly this was a sign so I started tearing into it. About this time I was in the dark ages of starting my own powder coating business so I coated the frame and rebuilt the wheels etc, then got too busy with work to do much and it sat idle for 2 or 3 years.
Fast forward to last week. My buddy is using my shop to rebuild his 89 suzuki 750 and basically hounded me hard enough that I tore into my motor. So here we are.
Honda CL77 resoration (Ann Arbor)Honda CL77 resoration (Ann Arbor)
This project was a good excuse to hook up the vapor blaster I bought a while ago. It is awesome. Here are three photos of before, after vapor blasting, and then after applying clear powder coating.
Transmission still needs a few things before it can be buttoned up.
Bushing C in the kickstart gear is totally trash. There isn't even any of the ridge left at all. This probably explains why all those gears seemed real sloppy. Also was able to set cases together which is exciting! I am very pleased with how the powder coating came out on the cases. I intentionally left a little dirt and roughness, and it came out just how I wanted it (see the close up)
Here are some photos I found of my wheel rebuild, the chrome was junk and the rims were pretty pitted so I powder coated them. Im not wild about the black, maybe some day I will rebuild with chrome.
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