Dealing with the weeping carburetor today. The leak seemed to come from the back of the bowl and I had a bit coming from the overflow. I cannot tell if the drain plug was leaking too (this is a newer square bowl carb). I removed the carb and changed the float valve from the old Keihin, which seemed spongy and weak, to a new one from a Keyster kit. I reset the floats, which are new, and changed the float bowl gasket for another new one. I noticed the the bowl made an impression on the first gasket, but not along the back edge where I think it was weeping. I ordered a new Honda gasket and a new Keihin float valve & seat. I cannot find a part number for the aluminum sealing washer for under the drain plug. If anyone can offer information on that, I'd appreciate it.
I also found that the large tube connection on the air filter is breaking away from the filter body. It appears that it was fastened with epoxy in just a few places and some have broken. Before I reinstall it, I'll epoxy all around it.
1964 CA77 RestorationI reinstalled the carb yesterday after the epoxy I put on the loose air filter inlet had cured. All went well. I attached my fuel bottle to the carb this morning and filled the carb bowl to check for leaks. All seemed dry except the bowl drain screw. I must find a new sealing washer for it or try an o-ring. I hesitate to use an o-ring because of the ethanol in the gas and I'm not sure what it will do to it. When I drained the carb after running the engine, the gas had turned from clear to yellowish. I think it's coming from the gas hose I use on my fuel bottle, but I cannot be sure.
After checking for leaks, I started the bike. 3 kicks with the choke on and the ignition off, then 1 kick to start with the ignition on. I'm a happy man. After the first run the other day, I checked the oil level and found that it had gone down a bit. I refilled it. After running today, the level seemed about the same. Spark plugs were clean. No oil leaks are evident anywhere. Now I'll turn to other tasks: I must clean out the gas tank again since a small amount of rust has reformed in a couple of spots; the clutch needs adjusting; the chain needs adjustment; the front wheel must come off to see what I've done wrong with the speedometer drive - it spins; and, I have to install the upper chain case/cover. I'm sure there's more.
Same one that designed the oil "filter"system and the placement of the carb and air filter... Finished fabricating a battery box today. I did not modify the stock battery tray at all. I might paint it when the weather is better. Still haven't decided how I'm going to permanently attach the charger wires. I might have to shorten them.
In test fitting the battery side cover, I can see that the latch screw is just too short for easy mounting. I took it off and compared it to the latch screw on the other side cover. It's the same length. I think that one is supposed to be longer than the other. I'll have to check and see if I can find the longer one.
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