Didn't realize I'd been neglecting my thread for so long. I see cyclon36 started a thread on the tensioner wheel in the meantime.
I took a closer look at the line on the large cam idler is actually a mold mark, with matching ones on both sides.
I've made a little progress. I've painted the engine cases, starter and misc parts with Duplicolor High Heat aluminum. It looks like a good enough match to the original to me. Right now I'm waiting for parts. Everything (for the engine) is ordered and should be here in the next week or two at the most. I've decided to go to the second oversize on the pistons (had 1st oversize CB pistons.) After some searching I found a new cam chain with the clip style master. I'll have to shorten it a few links, but that should be no problem. I had considered trying to install an endless chain, but decided that would be far too much of a pain.
I'm hoping to get the engine together by the time the weather turns good enough to start working on the bodywork and paint.
The labor of love (& nostalgia) begins!! 1963 CA77 DreamAlthough the clutch was working, the lever seemed extremely hard to pull. This along with the marking on the inside of the left cover convinced me that since I was this far into it I might as well check out the clutch. Good thing!!
First off all the bolts were loose. I believe PO had a sticking clutch and hadn't tightened them completely after freeing the clutch. I'm not sure about the springs. I don't believe they're stock. The length is 31.5mm (about 1 1/4") and the wire diameter is about .116". What I found inside was a messed up stack. The inside steel was a thin one (same as the other 5, for a total of 6) then a thick fiber friction plate ( about 5mm), steel plate, standard thickness fiber friction, steel, then 3 aluminum core friction with steel plate after, the final steel plate being against the cover. There were no wire rings in the stack, although the center hub has two grooves which are positioned for a thin first steel plate. What I believe will be right after reviewing LM's posts is starting with 2 steels, obtaining 2 more aluminum core frictions to add to the 3 I have and alternate them with the steels, ending with a friction against the cover. Hopefully the extra height from the one thick disc is what caused the interference with the cover and the hard pull. 63 CA78
Here's some more info on clutch and spring differences.
A set of springs and plates from LM cured my issues. http://www.honda305.com/forums/viewtopi ... gs&start=0 http://www.honda305.com/forums/viewtopi ... ht=springs 66 dream, 78 cb750k, 02fz1, 09 wing
Thought it's about time to update this thread again. I thought I had everything for the engine, but I hadn't taken a close look at the transmission, so after discovering bad gears and a worn shift fork ( which are detailed on a transmission thread- where I was set straight about replacing them) I grabbed a used transmission off Ebay and was able to make one serviceable transmission out of two. Then I took a good look at the primary chain and clutch basket (also detailed on another thread, and again set straight) which I am in the process of finding.
In the meantime I've done some of the little stuff such as painting and assembling the horn, assembling the right side cover, disassembling the extra rear shocks that came with the bike. Shocks on the bike have the plastic covers but I have one set of steel ones that are in good shape I'll use. The set with the steel covers had springs that had been shortened and one dampner was shot. I've yet to make a tool for taking them apart and assembling them. I wasn't worried about scratching them at this point, but I'll make something up before they go back together. The jam nuts on the rods were bottomed out and super tight. I had to use a visegrip to hold the rod, which scarred it some, but I doubt it will be a problem as I doubt the spring can be compressed enough to for the scarred area to hit the seal. I've also been looking over the other parts I'd already taken off and am compiling another list to order from Ohio Cycle. 63 CA78
Things are coming together, at least somewhat. I have obtained a primary chain(DID) that appears to have very little use, along with the drive sprocket that shows no sign of wear on the tooth tip, as others I have do.
Even better, I found what I believe is a Cush clutch setup on Ebay, although I could be wrong about that. Maybe someone can confirm from the pictures. It also came with the thick first disc and aluminum core plates and the two wires. There is absolutely no wear where the plates touch the basket, and along with the overall condition I think it had low mile useage. I'm not sure about the clutch springs. I have two sets, the ones from the old clutch have .115 inch wire (but no white paint) and the ones with the new clutch have .104 inch but are slightly longer. I think I'll go with the heavier but shorter ones. I now have a pretty good idea of what little things I need to put the engine all together and will order those shortly. In the meantime I have begun some body work, beginning with the front fender, which was tweeked, cracked and dented. The rear bracket was nearly torn off.
63 CA78
New parts are Cush Drive and do use the shorter springs. .............lm
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