The labor of love (& nostalgia) begins!! 1963 CA77 Dream

OldStan · Post by **OldStan** » Sat Apr 23, 2011 9:23 am

Thanks lm. I would have had no idea what to look for if I hadn't seen your posts on the subject.

LOUD MOUSE · Post by **LOUD MOUSE** » Sat Apr 23, 2011 9:35 am

Can ya show the pressure plate?. .........lm

OldStan wrote:Thanks lm. I would have had no idea what to look for if I hadn't seen your posts on the subject.

OldStan · Post by **OldStan** » Sat Apr 23, 2011 7:06 pm

Here you go. I haven't cleaned it up yet, all the clutch plates were stuck when I got it.

LOUD MOUSE · Post by **LOUD MOUSE** » Sat Apr 23, 2011 8:37 pm

It is a Cush. ...............lm

OldStan wrote:Here you go. I haven't cleaned it up yet, all the clutch plates were stuck when I got it.

OldStan · Post by **OldStan** » Mon May 23, 2011 11:17 am

Transmission is together with new rollers on the shift fork bolts and .040" offset cotters on 2nd gear. Now the engagement looks excellent with plenty of clearance in neutral. Now have a good left end countershaft bushing. Internal bronze bushing on countershaft measured like new, so I reused it. Of course I replaced all the seals, including the one in the starter sprocket that gets missed. That one was obvious to me since it fell out! I also installed new starter springs and plungers.

The case halves are assembled with Hondabond 4. My only concern there is one area where a screwdriver had been used (not by me) to split the cases right at the left front cover surface. It wasn't leaking there when I got it, so I think that should seal with some silicone and the gasket.

I ran into a problem putting on the primary sprockets and chain. The drive sprocket wouldn't go on the splines. After checking I found there are two different sprockets. I ended up using my original sprocket. The other sprocket I was going to use came with my primary chain. There was also another I got with my used transmission that wouldn't fit. When I compared them with my original sprocket I found that spline pattern was the same, but the ID of the splined area was smaller ( which would mean a deeper spline on the crankshaft.)

I did some searching and found this lm quote ;

The deep spline on the crank, clutch and drive sprocket was up to bike 1052546.
The shallow after that.

If I'm understanding this correctly, since I have the shallow spline on my crankshaft and my s/n is CA77E3182xx, then someone must have swapped the crank out with late model one?

OldStan · Post by **OldStan** » Wed May 25, 2011 2:07 pm

My enlightenment continues! While checking out a recent post on the cam sprocket centering, something caught my eye. It was in regard to camshaft installation and it mentioned tightening the bolt on the left camshaft. Problem was I didn't recall loosening such a bolt, or for that matter that there was one. Luckily I hadn't put the head on yet and discovered that some PO had assembled it without said bolt. The engine was running, although I don't know how long it had been run like that. There doesn't seem to be any damage to the splines, SO, I've go a bolt coming from Ohio Cycle. At least they're available.

Thanks to all who contribute to this forum, it's saved me a lot of grief so far, although I can't imagine that I won't miss something before I'm done.

LOUD MOUSE · Post by **LOUD MOUSE** » Wed May 25, 2011 4:37 pm

Caution.
The numbers are not for a CA77.
I don't have any data for that change for the CA77. .........lm

OldStan wrote:Transmission is together with new rollers on the shift fork bolts and .040" offset cotters on 2nd gear. Now the engagement looks excellent with plenty of clearance in neutral. Now have a good left end countershaft bushing. Internal bronze bushing on countershaft measured like new, so I reused it. Of course I replaced all the seals, including the one in the starter sprocket that gets missed. That one was obvious to me since it fell out! I also installed new starter springs and plungers.

The case halves are assembled with Hondabond 4. My only concern there is one area where a screwdriver had been used (not by me) to split the cases right at the left front cover surface. It wasn't leaking there when I got it, so I think that should seal with some silicone and the gasket.

I ran into a problem putting on the primary sprockets and chain. The drive sprocket wouldn't go on the splines. After checking I found there are two different sprockets. I ended up using my original sprocket. The other sprocket I was going to use came with my primary chain. There was also another I got with my used transmission that wouldn't fit. When I compared them with my original sprocket I found that spline pattern was the same, but the ID of the splined area was smaller ( which would mean a deeper spline on the crankshaft.)

I did some searching and found this lm quote ;
The deep spline on the crank, clutch and drive sprocket was up to bike 1052546.
The shallow after that.
If I'm understanding this correctly, since I have the shallow spline on my crankshaft and my s/n is CA77E3182xx, then someone must have swapped the crank out with late model one?