Topic: 1977 K7 Restoration Project

[77honda]

I was planning on doing some more work on my bike over the easter break, but ended up working on my sons 4x4, his gearbox began making a noise, we removed it and rebuilt it, found the input bearing worn.

Anyway I did manage some more assembly work on the engine,
Fitted the clutch and clutch cover
Fitted the alternator cover
Fitted the Gearbox cover.
Also fitted the Dyna-S Ignition.

Bored out the cylinder ready to hone, but when I looked at it one of the sleeves had a crack about 50mm long propagating from the bottom side, so I have taken the sleeve out and no looking for another one.

Anyway here are some more pic's

MIke

[77honda]

First chance to get back to working on the bike
Fitted an oil pressure gauge to the instrument cluster,
Fitted new valve guides to the head, just waiting on head to have seats reground.

Attached photo of oil gauge placement

[77honda]

Finally got around to doing some more work on my bike. The head has now been milled, valves and seat ground & lapped, new springs fitted.

I dry fitted the head, cylinder to the block and set up valves to check valve/piston clearences.
Next step is to fit piston rings, cylinder and head for final time, then I can put the engine into the frame. Hope to do this next week end, should have some picks to add.

[77honda]

Finally got engine assembled, Head is on and torqued.
Made a cheap ring compressor from PVC pipe connector, cut a 30mm piece off each end and then cut a slot in each.
See pic's. made it a little easier to fit cylinder, still needed an extra pair of hands though.

Hope to get the engine in the frame next week

[77honda]

Progress 2 days running, got home from work today and spent an hour or so fitting the cam, just a couple of small items to go and the engine is assembled, set the valve clearence then fit the engine back into the frame.

[77honda]

Finally got the engine together, Set & adjusted the valve timing, so it's ready to put into the frame.
Did most of the work myself, had access to a workshop where I work, has mill, lathe, bead blaster and a large centrifugal parts cleaner.

Some details on the overhaul
•   Crank inspected & balanced
•   Rods crack tested, shot piened, New rod bolts
•   Cylinder stock sleeves
•   new pistons, rings, wrist pins
•   New main & big end bearings
•   Heavy duty cylinder studs (APE)
•   New Inlet & Exhaust Valves
•   New valve springs
•   Head milled .0010”
•   New valve guides (APE)
•   Valve seats recut & lapped
•   New Primary chains & adjuster
•   New cam chain, sprocket, guide & Adjuster
•   All new Ball bearings
•   Cases bead blasted & painted (VHT Cast Aluminium)
•   Cylinder & head bead blasted & painted

Couple of photo's of finished product.

[hoodellyhoo]

Looks great! Thanks for keeping us updated.

[77honda]

Holidays are great, at least I get to spend more time in the shed, (after doing all the family things)
Had a quite new year so got up early (raining again) and finished of the engine, bolted on the covers also started stripping and cleaning the carbies, will take pics of this as I go

[77honda]

Stripped all 4 carbies model PD41A

I have cleaned them and then soda blasted each, boy it is a meesy job but it sure does clean up the carbies.
I did find that on the throttle shafts and choke shafts wjere they enter the carbs is a small seal some are felt and others rubber. It looks like the seals on carb 1 & 4 are felt as they have only one "open" end the other is plugged, all other have a smal rubber seal. My rubber ones are hard so need replacing, I did a search and it looks like these items are not avialable, has anyone used "o"rings in place of felt. Also what sort of clearence should the shafts have in the carb bodies.
I have reassembled 3 of the carbs

[77honda]

Back again, Got a lot done today as we have rain, more rain, so spent the best part of today in the shed.
Engine is now fitted in the frame, wheels are on, now it's time for the electrics. Not my best area, so will be searching the threads for help on this.

Fitted on side of the exhaust system, not bad condition a couple of scratches a small dents, but will be ok for now

[Stev-o]

Nice attention to detail on this rebuild, looks great.
You have been working on this quite awhile!

[77honda]

Thanks, yes it's been a while, work committments have slowed me down. Will be busy for next two months with work, so I don't expect toget a lot done until after April, but who nows.

[77honda]

Managed to get the carbies rebuilt, new gasket kits in all.
Found the seals on the throttle & choke shafts were worn, so decided to replace them. Could not find any part numbers in Honda part listing.
So pulled one out, it was a small lip seal 14mm od x 10mm od x 3mm wide. Could not get any here in Australia, but found them in US

These are from  "Motion Indutries"
10X14X3 VG-NBR METRIC SEAL                 
STOCK                                     
Item No..........: 0059751
Price............: 2.770  US
Eventually replaced them with "O"rings
Throttle shaft - 10mm ID x 2mm cross section

Choke Shaft - 6mm ID x 1.7mm Cross section
1. Removed the outer seal retaining plate, with a small screw driver, just gently lever it out
2. Remove old seal, clean, and install new "o"ring
3. Reinstall outer seal retaing plate, use a small socket that the seal plate fits over. Gently tap in with a small hammer, using the socket as a punch.

Do same for choke shaft

[750]

Been here, done this. I think ur doing it better. Subscribed

[77honda]

Was hoping to start the bike this week, but my oil filter adaptor has not arrived.
Have to go away again for work on a new roster so 10 days away 4 days at home, will attempt to get it started next week (if adaptor turns up)
Been workin on this for over 2 years, but with my job spend a lot of time away, at least it pays the bills.

[77honda]

Finally back from the sticks, been in Moranbah (Central Queensland) til Feb 2012 then only home for 3 weeks then was sent to St Helens in Oregon USA. Got the spend 12 weeks there for work, then took 2 weeks off (Hoildays) Flew my wife over, hired a car and drove around. Spent time in San Franciso, then Houston, Dallas. Had a great time.

But now I can spend some time on getting the bike finished.
Tank, side covers, head light bucket & guards are all primed and have first colour coat on them, just waiting for some fine weather to finish them off

[Stev-o]

Like the color. 

What did you do in Houston & Dallas? Buy boots & a hat?!

[77honda]

Nearly finished, been a long project, just waiting on ignition then ready to start it

[dhall57]

Hey 77, dhall here in NC. Saw your before pic in 2008 and your near finished project pic today. Great work and a good looking K7. Really like the color. When you tackled this project did you ever imagine it would take 5 years from start to finish. Your job keeps you away from home for long periods of time, what type of work do you do?

[Bankerdanny]

Antares red, nice. In that color it's obvious that it's a cousin of my 77 Goldwing

[77honda]

Thanks dhall, no did no think it would take so long, but was only home for 3 months last year.
My job is planning maintenance shutdowns (turnarounds) for our company, we have 4 large chemical plants in Australia and 5 across USA. Got to spend 3 month in St Helens, Oregon last year.

[77honda]

It's running, we set up the Dyna ignition using a test light, then adjusted the carbs, after about 20sec on the starter she fired up. All four cylinders working, but no.4 seems to be colder than the others. Oil pressure is 65psi.

Will post a video of it running when I find out to do it.

[77honda]

Ok, loaded video on onto you tube, so here it is

http://youtu.be/2KIOc9FZglA