Honda305.com Forum

Greetings,

I'm new to the forum. Just wanted to introduce myself. I just bought a 1966 CB77, in many pieces - photo below. Back in the day, I had a CL77.

I was about to start sending out parts for chrome and powder coating when it occurred to me that I should probably first check that I actually have enough parts to put a motorcycle together. So, I started assembling, and found that not much is missing. I've started ordering those parts that are missing or in need of replacement. I've also started realizing I'll need lots of advice as the project moves forward - this forum appears to be a great place for such advice.

First item - mufflers. Mine are in such bad shape that it's not clear I can restore them for less than the cost of good reproductions ($1,400?). The right one has rusted all the way through in a few spots. I'll be looking for original mufflers in better shape than mine. Photos below, suggestions welcome. I'll put up a post in the Wanted section of the forum on this subject.

Phil

If you are looking to sell those mufflers let me know

jugger18,

Not the kind of response I was expecting, but I'll keep it in mind. For now, I'm going to pursue repairing the mufflers.

Phil

I've been away from the project for a while. Realized another thing I should check before going too far - see if the motor works.

Since the bike is still largely disassembled, I'm hoping to do a minimal setup. As far as electrical, here's what I think I need (aside from the obvious, like spark plugs & points):

1. Battery.
2. Starter motor.
3. Starter switch.
4. Starter solenoid.
5. Rectifier.
6. Ignition switch.

What have I left out?

Does anything in the headlight housing, other than the starter switch wire, need to be connected?


Non-electrical

This will be the first time the motor has run in over 10 years. It turns over smoothly by hand, and has some compression. I'm planning to remove the cylinder head cover (item 5 on the parts diagram) and douse the timing chain / camshaft area with oil. I'm also thinking about filling the cylinders with oil, draining, doing some gentle cranking to distribute the oil, then rinsing with a gas/oil mix.

What oil should I use? Full synthetic?


Exhaust: I bought the repop mufflers from David Silver Spares - what a great bang for the buck! I also bought the repop down pipes - not so great - they do not seat properly in the engine's exhaust ports - the flange face angle is off by 5 degrees or so. Has anyone else had this problem?


Any advice on any of the above would be appreciated.


Phil

Hi Phil
Can you post a picture or two of your DSS mufflers? I'm trying to ID the origins of a set of repro's I recently bought.
Thank you
Steve

Steve,

Here are some photos of the mufflers.

They came with diffusers, which will require some fussing / fitting / finessing to install - that's why they are not in all the way.

Phil

Thanks Phil
They look like the same manufacturer as mine. Did you mention earlier whether they have drain holes or not? My mystery set doesn't. If yours don't either, because of the amount of rust on my baffles I am going to speculate mine are a set of DSS mufflers that got side tracked and lost for a number of years. Thank You very much for the the helpful information.
Steve