Swap meet find- 67 Scrambler restore

OldStan · Post by **OldStan** » Sat Nov 02, 2013 10:02 pm

Now that I think about it, the sleeve was advertised as a CB77 sleeve, shouldn't that be the same as a CL77, or was that my mistake?

OldStan · Post by **OldStan** » Tue Jan 21, 2014 12:07 am

Finally making some progress. Transmission is back together with Xed gears. Only problem was with the NOS kick start shaft. When I put the countershaft together it wouldn't quite sit on the dowels, a little too long. I found the machining on the shaft on the pall end wasn't quite finished as far from the end as it should have been. With some careful grinding in the taper of the bushing I got it to fit perfectly.

The frame is cleaned up,wiring harness is in, wired to a regulator instead of the diode setup,which is still in place for appearances. Managed to get a couple of keys made locally. I have an original but it is cracked, didn't want to take chance of it breaking off in the switch. Same key works the steering lock, so they must be original.

Lately I've had to choose between riding the Dream and working on the Scrambler. This crazy weather has been good for afternoon riding. Sunny,high 60's, and no rain. Not normal Northern California January weather!

Next is assembly of the head. The valves are lapped and all parts are cleaned, with new bearings,just need to get to it.

LOUD MOUSE · Post by **LOUD MOUSE** » Tue Jan 21, 2014 7:54 am

You know that bushing had a inside taper on one end and not the other?. .lm

OldStan wrote:Finally making some progress. Transmission is back together with Xed gears. Only problem was with the NOS kick start shaft. When I put the countershaft together it wouldn't quite sit on the dowels, a little too long. I found the machining on the shaft on the pall end wasn't quite finished as far from the end as it should have been. With some careful grinding in the taper of the bushing I got it to fit perfectly.

The frame is cleaned up,wiring harness is in, wired to a regulator instead of the diode setup,which is still in place for appearances. Managed to get a couple of keys made locally. I have an original but it is cracked, didn't want to take chance of it breaking off in the switch. Same key works the steering lock, so they must be original.

Lately I've had to choose between riding the Dream and working on the Scrambler. This crazy weather has been good for afternoon riding. Sunny,high 60's, and no rain. Not normal Northern California January weather!

Next is assembly of the head. The valves are lapped and all parts are cleaned, with new bearings,just need to get to it.

OldStan · Post by **OldStan** » Tue Jan 21, 2014 9:02 am

Yes, I just made the existing taper a little deeper, just enough so the bushing would touch large part of the shaft, .040 " or less. I didn't measure it, but it wasn't much.

OldStan · Post by **OldStan** » Sat May 10, 2014 9:48 pm

I've gotten way behind on posting! The last 4 months have been crazy. I've retired - the second and last time, at least that's what I tell everyone (last working day was April 6th.) The last month at work was a process of transferring my work load and even some overtime- so nothing got done on the bike. Since then I've painted my house (2 coats, by hand), along with planting a garden and doing all the things I've been putting off to do "when I retire." It finally caught up with me.

But I have made considerable progress in the moments I could steal (to hot or to wet to work outside.) Today was a major plus. I got it started and tuned. Static timing was right on when I used a timing light after, and max advance was on the money. No ride yet, still need tires and a battery. Borrowed the battery out of the CA77 to time and start it.

I was concerned about repainting the tank and side covers, but managed to remove strips someone had put on without major damage to the original paint. The paint color is different where the stripes were, but not enough that I'm going to worry about it. I had a hard time finding the right size and color fuel line locally, but a small equipment shop had it, just had to talk to the right person.

Next step is removing the existing tires and checking and cleaning up the wheel bearings and brakes.

Stock tires were 3.00 x19 in the front and 3.50 x 19 in the rear, right?

Anyone have a line on an AGM battery that will fit? Unfortunately the one from my CA77 is a little too wide.

I think I should have it ready to go for the AMCA National Meet in Davis, CA in June, at least that's my goal.

mike in idaho · Post by **mike in idaho** » Sat May 10, 2014 10:45 pm

OldStan wrote:Not a good day. Picked up a NOS sleeve on eBay. I had no problem getting the old sleeve out, cleaned the sleeve, froze it overnight, heated the barrel assembly up and started to put it in. It should have slid in easily, but it barely got started. The other sleeve slipped out, i had to put it back in. I knocked the new sleeve back out, let it cool and measured it. The OD is about .005 inch larger than the old one. Hadn't thought to measure that, had compared everything else. It wasn't advertised as oversize, didn't even realize they existed. I guess I have two choices, get the barrel bored oversize for the sleeve or find another sleeve.

I wouldn't bore the block, a tight fit is desirable. Heat it up to about 400° and see if it will drop in. Set the block on a pair of bricks in your oven(if the wife will allow it), getting it heated up evenly will help. Place a weight on top of the sleeves after they drop to hold them down as they cool. Be sure to measure the bore for piston clearance after installation.

OldStan · Post by **OldStan** » Sat May 10, 2014 11:26 pm

Well past that point. I had tried what you said, but there is not that much expansion. I actually used my propane BBQ and an infrared temp sensor to try. The other sleeve fell out, but this one wouldn't even come close to going in. The machine shop took care of it,then bored it 1st oversize.