Well I’d say you really made out! And you didn’t have to sell one of your bikes to do it!
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Honda CL77 Scrambler project
- Thread starter willis
- Start date
Well I’d say you really made out! And you didn’t have to sell one of your bikes to do it!
Well the xs2 is still in line to go up for sale once I get a few more repairs made. It will ultimately fund this build.
Tonight I dug into the spare motor for a condition report. I really am surprised at how simple it actually was. At first it was looking good.
And then….
It’s weird how it holed the piston on the side like that. The wrist pin keeper on that side was gone too. A nice gouge in the cylinder and the rod almost seems like there was a coating that chipped off. I’m going to clean it more tomorrow with some solvent to check that out.
And then….
It’s weird how it holed the piston on the side like that. The wrist pin keeper on that side was gone too. A nice gouge in the cylinder and the rod almost seems like there was a coating that chipped off. I’m going to clean it more tomorrow with some solvent to check that out.
The rod cleaned up and it was cooked on oil buildup. A few spots where the copper coating is gone and also some rough casting marks on the rod end? I didn’t get too aggressive with my brass brush but those castings seem awful rough for a rod.
Possible it's molten aluminum stuck to the rod?
Could be. You are right about the proximity to the hole in the piston I scraped a little at it with an exacto knife. Not exactly an area i am comfortable getting too aggressive with scraping. I will dig into it a bit more when i've got some free time.
If it turns out that is a blob of piston stuck on there, it'll have to come off one way or the other. You wouldn't want to risk it coming off at 5k rpm and rattling around in the sump.
winner winner chicken dinner. You were right. I did some careful scraping with the exacto and was able to get those spots to pop off. There is the area where the copper coating is gone, but those "castings" are now smooth.
Glad it came off easily, but it looks like it's all for naught. Near as I can tell from a pic, that con rod is toast. Metal has extruded out the side of the rod from the piston being way out of balance I'd guess... or maybe oil starved. Can you use the wrist pin from the other piston and push it in the rod to check how much play is in there?
... if that were a completely irreplaceable rod, I'd consider over-boring and sleeving it. Otherwise, its time to look for a replacement, unless that is normally a bushed small end in the first place?
I had to drive the pin out pretty aggressively on that piston. It would not drive out from that side though, I had to push from the outter side in. I'll check it in a bit. Fortunately this is just a spare motor. The one in the bike has forged pistons in it. I will likely be piecing together the best of both motors.
Stripped her down to a roller today. Finding lots of little issues. I was expecting some, but really starting to realize how cobbled together this bike is. My main objective is to tear into the motor to see the condition. I need to decide which one is better. It may ultimately be a mix and match of the better parts. Fingers crossed to find some spare time tomorrow to dig in.
Tore the top end off this motor a few days ago. The cylinders look pretty decent and hoping a hone will clean them up. There is a contact mark on top of one of the pistons, as well as a bent valve. Not sure when the calve bent though. Could be from trying to kick through with the wrong plugs installed? The wrist pins show some galling/corrosion, so it might be in order for a new set regardless. Right now I just have it disassembled and bagged/tagged. It all needs a good cleanup. Thinking next week i will pick up a gallon of Kerosene and make a make-shift parts cleaning tank. I really need to invest in an Ultrasonic cleaner too.
LOL, I just noticed the "all-thread" cylinder stud in the pictures above... (insert heavy sigh here)
I knew this project would be a slow one. My family just moved again from the country back to the city. With this move we are downsizing quite a bit, so I knew everything would be on hold for some time. I’ve got to completely set up a new workshop, so all my other projects will lay in wait. With this in mind, I decided to farm out the motor rebuild. My buddy’s brother has rebuilt several of these motors so I feel confident in having him do the work. The only downside is he lives about 6 hours away in Pittsburgh. With all this in mind, we packed up both motors the other weekend while he was in town knowing this would be a winter build for him. Today I got a text from him stating he was way ahead of schedule and sent me these pics. Very happy to say the least.
Now I’m going to have to step up the rest of the build. I wasn’t planning on a shiny clean unit. I can feel my wallet getting lighter already.
Now I’m going to have to step up the rest of the build. I wasn’t planning on a shiny clean unit. I can feel my wallet getting lighter already.
That looks great...it was a good move to have him build your motor. 
Leaving a little crust certainly saves some time and money. Now you’re really committed! Looks great…can’t wait to see the rest.
