darboots - 1961 CA77 from boxes

darboots · Post by **darboots** » Sat Apr 29, 2017 4:54 am

Small update:

Things have slowed down a little since I'm now gainfully employed for a few months.

I've mainly been working on the rear shocks. When I bought the bike, there were two pairs of rear shocks included, one with red covers and one with black.

I managed to find some suitable seals, which took a couple of weeks to arrive:

These were fitted to the internals:

Neither set of covers were in particularly good condition, so I sent off for a set of red covers to paint to match the blue frame. Then I found that I could only get one shock back together successfully due to problems with the threads, and I've now purchased yet another pair of shocks, this time with the correct metal covers. Unfortunately, one of those covers has a tear, so it looks likely that I'll have to somehow panel beat and/or fill that before painting...

G-Man · Post by **G-Man** » Sat Apr 29, 2017 8:21 am

Any progress is still progress....

G

darboots · Post by **darboots** » Sun Jun 04, 2017 9:32 am

Some bit of progress, namely that the front end now has a grey damper and front fender (or mud guard as us Brits call it). Had to strip most of the front end back down to fit the darned thing, but I'd rather have done it that way way than risk painting from the aerosols during the colder months.

I hit a snag... I was refitting the refurbished rear shocks, but the rubber bushes (shock to frame and swingarm) need replacing. The ones I had were NOS, but seem to have been purchased around 15 years back. They've gone squidgy! When pushed onto the upper mounts, the bushes are just oozing the rubber material, and not staying intact.

CMSNL are out of stock, and NOS parts on eBay are around $15 each. Does anyone know of an alternate source, or if they're available as poly bushes or similar?

tech54K · Post by **tech54K** » Wed Oct 04, 2017 1:38 am

Seadog wrote:CMSNL has the mudguard holder, part no. 0314-259-000, for 12 euros. Do you have the rubber mudguard?

http://www.cmsnl.com/honda-ca77-1960-19 ... _K0nzKZO7w

This is a great project!

darboots · Post by **darboots** » Fri Apr 20, 2018 7:42 am

Can't believe it's been almost a year since I updated this thread.

Just been sorting out the pictures since the ransom messages from PhotoBucket have been ignored. Sorry if some appear to be incorrect! Just let me know and I'll fix them.

I've been trying to sort out the headlamp wiring and have rebuilt the ignition switch several times! I now need to get the bike running reliably, and then take it for an MOT and get the registration sorted out with the DVLA....

darboots · Post by **darboots** » Tue May 01, 2018 8:43 am

I'm almost ready to get the bike MOT'd, but cannot get it to run fo more than about 5-10 minutes from cold. When it stalls, it seems that it then won't start until cold again.

The needle valve keeps sticking until I tap it with the handle of a screwdriver. I need to clean the spark plugs regularly with a wire brush. Then fuel drips from the carb overflow... Argh! :(

I'll most likely start from scratch again and check the valve clearances, plug gaps, points gap, timing, etc., but this is really frustrating.

What spark plugs do people use on the early CA77's (10mm)? I think mine are currently CR7ES. Is there a better alternative to the C-10H?

G-Man · Post by **G-Man** » Tue May 01, 2018 10:22 am

Sounds like the float bowl gasket may be swelling up and trapping the float. Ethanol in the fuel affects some rubber carb gaskets.

For plugs - check out what people are using in Honda 50s. Only the early dreams had 10mm (C range) plugs. Later bikes have 12mm plugs

G

darboots wrote:I'm almost ready to get the bike MOT'd, but cannot get it to run fo more than about 5-10 minutes from cold. When it stalls, it seems that it then won't start until cold again.

The needle valve keeps sticking until I tap it with the handle of a screwdriver. I need to clean the spark plugs regularly with a wire brush. Then fuel drips from the carb overflow... Argh! :(

I'll most likely start from scratch again and check the valve clearances, plug gaps, points gap, timing, etc., but this is really frustrating.

What spark plugs do people use on the early CA77's (10mm)? I think mine are currently CR7ES. Is there a better alternative to the C-10H?