eyhonda - 63 cb77 cafe project

[eyhonda]

Popped on the head and torqued down the bolts. Getting closer!

[eyhonda]

Using a small floor jack, the motor slid in.

[eyhonda]

I got some Dunstall reps and header reps from Ohio Cycle.

[eyhonda]

I fabbed some L brackets and bolted them to the seat pan. I got some hardware for clipping in the strap. Tada, another item off the list.

Also, I've assembled the side covers, kickstarter arm, clutch, filter, all the oil filters and the chain. The shifter needed a lot of attention here. I've adapted a shift pedal from a CBR954rr. It required the shift rod from the same model and a couple of Heim joints. Eventually, I needed to shorten the attachment to the pedal arm. It was too long and had too short of a travel and not enough leverage. It was difficult to shift prior to the readjustment. Also, it was difficult to shift due to the motor being dry for such a long time. It eventually loosened up enough to shift smoothly. Luckily, I didn't have to open the transmission case. I plan to this winter to cross the 2nd and 3rd gears.

[eyhonda]

Last Friday, I finally started the motor! It fired on the 5th kick! I only had a handful of small issues but they are fixed as of this writing.

1. The float needles were stuck causing overflow. Easy fix. Just tapped the carbs til they dropped down.
2. The fuel wasn't flowing in the reserve position. The tank turned out to have some residual debris from the cleaning last fall. I just rinsed it a few more times.
3. There was some oil pooling in the right cover under the crank. It turned out to be a missing oil seal. I deleted the starter. So, the oil seal was in the starter gear. I just popped the starter gear back on with a new seal. Then, I remembered an extra oil seal in the kit. This happened to be the oil seal required if you have no starter. I can just change this later. It's fine now.
4. I had the shifter problems stated earlier. I little more adjustments with the clutch cable and the shifter resulted in a better shifting.
5. The fuel leaks a little past the cap when the fuel swishes around near the top. Not sure why. The gasket is new and the cap is tight.

Overall, I'm very happy so far with the build. No leaks, no smoke, no bad rattles. Just fine good old SOHC Honda motoring. Awesome! It's a little finicky starting from cold. I have only 5 miles on it in the neighborhood to shake out any problems before I take it on the road. Next up is insurance and plates. I can't wait to take it past 40 mph!

I still have to finish the seat. I need to paint it and reupholster it. Also, if you notice, I didn't attach the side panels. I like it without it so far. I made little brackets to hold the badges. I wanted to emulate the CR77 as much as possible without paying for an alloy long tank. I had one on my CB400r but it was $500 8 years ago! I may try to get a CR110 tank later as I believe it fits. I think this is it for the summer. The last 6 1/2 months was a long but fun journey.

[maia]

Nice Job! What's that front tire? I'm looking for one and so far have come up with Avon AM26 90/90. Thanks.

[eyhonda]

Thanks! The set is Michelin Gazelles in the stock size. Modern tread pattern. Supposed to be scooter tires but will work on our bikes due to it's relatively light weight.