This project started almost 30 years ago, was abandoned and within the last year has come back to life. Ever since I started motorcycling with a CB160, almost 60 years ago, I’ve wanted a CL77. Finally, I bought a non-running 67 CL in the 1990s. Sometime later I acquired another CL which I figured would be good for parts. I started buying all the shiny parts from a Honda shop in Manhattan with the intention of doing a full restoration. Among the things I acquired back in the 90s was a NOS exhaust with integrated muffler. However, it wasn’t until last year, after coming close to selling it all, I decided to go ahead and rediscovered my passion for wrenching.
I’ve visited honda305.com many times through searches for answers to the many questions I had regarding this bike but only today did I discover this forum for people to chronicle their restoration projects. I knew it would be fun and most likely helpful to share my efforts with like minded enthusiasts.
A short recap makes sense as a lot has happened since my first challenge to unseize my two engines. When we moved to our present location, I did not have enough storage for all my bikes so the two CL rolling chassis I had were stored outside as were the two engines. You can imagine what 18 years in the elements did. Thankfully, the humidity in Montana is never very high so the bikes didn’t rust into the ground. However, the two engines were very much seized. I managed to get the one engine that had a good title unstuck after much effort; the other is still seized. However, the second one did yield a good transmission amazingly. Between these two bikes, I figured I had a good start on one complete bike.
Over the past year, I have taken everything apart that could come apart (including the brass plate on the chrome horn cover!) I’ve created spreadsheets listing every part, nut and bolt, listing its condition and planned restoration. I’ve also discovered all the parts I was missing or were too badly damaged and without upsetting domestic tranquility, purchased them slowly from the many vendors I found on line.
My goal is to build a motorcycle that looks like it is brand new. As the frame did not belong to this motor (the title matches the engine case VIN) I’m not worried about a concours level restoration. So I’ll accept stainless substitutions and other things that will look good.
So far, the only restoration work I’ve done is to have the engine and aluminum parts vapor honed and the frame sandblasted and painted (I’m going with silver and black). I also did a through inspection of the transmission and ended up with installing the reverse cotter which I hope will give me decent shifting.
There is clearly a lot of work to do yet. I’m still inventorying all the parts, cleaning them with my HF ultrasonic cleaner and cleaning off the rust with Evaporust prior to final polishing or replating. I’ve got enough good chrome parts that I may just locate replacements for anything that I might have sent out. But there’s enough to be replated that I’ll use some service for that task. My goal is to have all the parts that aren’t being painted ready for reassembly. In the spring, I’ll finish sandblasting frame parts and stripping the paint off the metal work for a final painting.
I will post periodic updates as I make more progress. If I figure out how to post pictures, I'll include them. Thanks for reading and wish me luck!
