1966 Honda CL77, 305 Scrambler Restoration
Before
After
The original bike - October, 2011
Before - right side
Before - front
Before - speedo
Before - rear
Before - engine
Before - engine close-up
Before - rear wheel
The dismantle begins
Tank emblems, battery cover & strap
Right side air cleaner cover
Gas tank petcock
Carb fuel leakage on engine cases
Left 3/4 view before restoration
Ignition switch wiring
Ignition coils and wiring
Close up of gunked up carbs
Spark plug hole - left cylinder
Missing bracket for rear stop light switch
Right side view of coil and cylinder head
Ignition switch wiring and frame
Original generator rectifier
More carb leakage
Old wiring in headlight
Removed ignition and engine wiring
Bike partially dis-assembled
Air cleaners and mounts are removed
Front view partially dis-assembled
Bike with most of the wiring removed
The old engine harness
Engine and transmission removed
Parts to be refurbished
Starting to remove fenders and wheels
Parts ready to take to the powder coaters.
Cam chain tensioner
Another view - Cam chain tensioner
Time to tear into the motor - October, 2011
Back side of motor
Front side of motor
Right side of motor
Alternator and drive sprocket
Off with its head!
Bottom of cylinder head - valves and cam sprocket
I found a broken ring on the left cylinder. That probably accounts for the gunk.
Close-up of shifter mechanism
Original cylinder bore in good shape
Gear selector mechanism
Left side of engine with primary drive & clutch removed
Starting to remove the bottom of the crankcase
Starting to remove oil pump cover
Crank shaft and transmission
Case needs cleaning!
More cleaning needed!
Checking gear box
Despite the grungy oil, all gearbox pieces were in good shape. Way to go Mr. Honda!
Starting to clean components
Side view of engine internals
The wheels are pretty messed up
Inside view of front hub
We disassembled the wheels in order to reuse the hubs with new rims
A picture showing the spoke pattern
The work begins - November, 2011
The engine went back together with new bearings, rings, seals, cam chain and gaskets.
All the internal parts showed virtually no wear
Setting valve lash
Primary drive & clutch installed w/ oil centrifuge
Front view of refurbished motor
Close-up of the primary sprocket & generator
Checking the cam chain tension
We cleaned and painted the side covers
Getting ready to install the clutch push rod pivot
The frame is back from the powder coaters!
Now we can start to re-assemble the bike
Motor mount bolts installed
Prepping head stem bearings
Swing arm & Hagan shocks installed
Carb and coils fitted
Lower triple clamp installed w/ steering head damper
We installed new air cleaners, intake hoses and fitted the shifter
The tool box w/ air cleaner assembly is fitted
We refurbished & installed the front fork assembly
Frame wiring & top triple clamp installed
We started sorting out wiring and cable runs
We re-wired the headlight
Close-up of new headlight wiring
There are not many miles on this bike
It's starting to look like a bike again
Now to make the wiring work!
Right side cover is on
We took the seat apart to see if we could fix the padding, but decided to take it to a pro
Seat w/ new foam & cover - much more comfortable
The seat looks better too!
We had all the exhaust pipes & fender brace re-chromed. The pipes look great!
We spent hours polishing the hubs. We also put in new brake shoes.
The original tank & fenders are back from the painter in their matched stock silver color.
Re-painted gas tank
Side view of repainted fenders
Top view of repainted fenders
We mounted the painted tank and fenders
View of the painted tank from the rear
Newly chromed exhaust pipes on bike
Tank emblems installed
Sorting out cables
The new front wheel with the new spokes installed
Left view of new wheel
The new original style, front tires are here
We mounted the front tire on the wheel with new tubes
Then we installed the handlebars and wheel on the bike
The rear fender is mounted on the bike
The new rear wheel with new spokes and tire
New wheel spoked and trued
Left side of rear tire mounted on wheel
Right side of rear wheel with new tire and sprocket installed
The bike wouldn't be complete without Snuff-or-Nots!
Snuff-or-Nots installed in exhaust
Open Snuff-or-Nots
Restored - ready to ride!
