shelly (65 cb77)

mobilyte · Post by **mobilyte** » Wed Jun 30, 2010 4:06 pm

bought a powerstar branded agm battery for $39 shipped from a distributor out of mokena IL. they do business under several websites (bluegrass battery on amazon, batteryjack.com, powerstarla.com).

the specs/size were right, still bought it knowing the +/- terminals were on the wrong sides.

i ended up receiving battery part #PM9A-BS, it has met my expectations so far.

mobilyte · Post by **mobilyte** » Wed Jun 30, 2010 5:01 pm

kicked things off by replacing a wrong center stand spring with a cleaned up spare.

installed the toolbox, starter solenoid and deliberately put the ground cable on the wrong side of the frame.

the positive connector from the fuse could reach the battery, but the ground cable and positive cable from the starter solenoid werent fitting.

i put the ground cable back on the correct side of the frame and it fit.

i replaced the solenoid to battery cable with a spare solenoid to starter cable (much longer), this will get more attention later.

mobilyte · Post by **mobilyte** » Fri Jul 02, 2010 5:34 pm

wasnt planning on doing anything with the front end, but the paint on the fork cases was pretty beat.

one of the fork seal holders spun off by hand, the other took a lot more effort.

stripped and blasted the lower fork cases (exterior only), rinsed out the inside with lacquer thinner. used tape to cover the opening down to 90% of the threads, then sealed/painted the cases.

the fork seals looked good and werent leaking. i cleaned and polished all of the parts, reassembled and filled with synthetic atf.

mobilyte · Post by **mobilyte** » Mon Jul 12, 2010 4:56 am

had to do some serious repair to the existing lower fork covers since all of the spares are off alloy forks. removing the dings/dents wasnt a problem, but one cover had a 1/4" by 1" gash.

my cousin came up with the idea of taping the outside of the missing section, filling with epoxy on the inside, removing the tape, and finishing the outside with filler.

all of the top fork covers are the same (steel vs. alloy forks), so i used the best pair. all the covers were primed/painted.

polished up half a dozen of the chrome fork ribs and picked the least pitted pair...dont forget that o-ring!

mobilyte · Post by **mobilyte** » Mon Jul 12, 2010 5:00 am

bead blasted and polished the fork top bridge, polished some discoloration off the handlebar holders/bolts.

mobilyte · Post by **mobilyte** » Mon Jul 12, 2010 5:05 am

"the machine" held up the front of the bike while i installed the forks

mobilyte · Post by **mobilyte** » Mon Jul 12, 2010 5:46 am

didnt want to do a complete wheel rebuild yet, so:

had a mechanic remove the tire (the only task in this project that was outsourced)
gave the original DID rim a rough cleaning with scotchbrite pad and wire wheel
clean/polish most of the rim and bead seat, used a foredom to get between the spokes
bead blasted the outside of the brake hub...dont lose those felt brake cam dust seals!
clean/polish the brake linkage parts, including the brake stopper arm
install new rim strip, tube and 2.75/18 michelin gazelle tire (mechanic again)
clean the speedometer gearbox (important note for future reference: came with this bike and assumed to be factory original, though the bike had no speedometer)
brake lining and pads looked okay after some cleaning

Honda305.com Forum

honda305.com Forum

shelly (65 cb77)

power

assembly

forks

fork covers

forks

assembly

front wheel