Topic: 68 CB77 Fork Disassembly....How?

[MCRider]

Does any one know how the fork tube/leg combo comes apart on a CB77. I've got the circlips off the seals and the bottom bolts out as well. I would think it should pop apart, but it ain't having it.

[jgger]

Does it have the chrome caps at the top of the lowers? If it does ( and memory serves me) those caps are threaded to the lowers and need to be unscrewed. It takes a special tool simular to the one for adjusting the original rear shocks. I think they call it a spanner. A hook looking thing with a pin on it.

Hope that makes some kind of sense.

[MCRider]

Does it have the chrome caps at the top of the lowers? If it does ( and memory serves me) those caps are threaded to the lowers and need to be unscrewed. It takes a special tool simular to the one for adjusting the original rear shocks. I think they call it a spanner. A hook looking thing with a pin on it.

Hope that makes some kind of sense.

Yes it does make sense. But doesn't help. Their were two types of forks. The one you describe is the earlier used up till about 65/66. On mine, the chrome cover is not threaded, it is just pressed on. It comes off with a twist and a pull. I've seen the spanner you refer to, maybe a pin wrench. I almost bought one, they are on eBay, till I found out it won't work on mine.

Once you get the chrome cover off, the seal is exposed and a circlip that holds it in place. I've got the circlip out. Now I need to get the tube out of the leg. A rapid pull on it should pop the seal out and the tube with it. But it sounds / feels like it's still hitting something firm. I've got the bolts out of the lower legs.

[jgger]

Have you tried the 305 forum. There are some knowledgeable people there, plus they have cleaned the spam off of the site. If you could get him to respond, a member here " old scrambler" would probably know.

Sorry I couldn't help.

[MCRider]

Have you tried the 305 forum. There are some knowledgeable people there, plus they have cleaned the spam off of the site. If you could get him to respond, a member here " old scrambler" would probably know.

Sorry I couldn't help.

No I haven't. Spaced it, should have gone there first. Thanks!

[Stev-o]

Have you tried the 305 forum. There are some knowledgeable people there, plus they have cleaned the spam off of the site. If you could get him to respond, a member here " old scrambler" would probably know.

Sorry I couldn't help.

No I haven't. Spaced it, should have gone there first. Thanks!

Hey Ron...do you know forum member "Old Scrambler" [Dennis]?   As jggr mentioned, he should know as he has a CB77, the ol' scrambler.

[Bodi]

Well, the Honda shop manual isn't any help. There is a cross section diagram that doesn't tell me much, maybe it will help you. CMSNL has the fiche (parts book more likely) page, and I found it also less than helpful. I have had them apart, but it was 45 years ago or so and I don't recall anything about the job.

[Magpie]

If you are on Facebook search for Bill Silver and shoot him a message asking about it. He's the guru of 72's and 77's.  Also join the Honda 205 & 305 SOHC Twins group on Facebook.
https://www.facebook.com/groups/1580127085650350   
Cliff.

[Bodi]

The Clymer book has some better diagrams. These forks are different from SOHC4 types. The spring is at the bottom of the fork leg pushing up on the end of the tube and it looks like the lower is held on only by the seal and its circlip. The working piston bits are held to the tube by another circlip and slide inside the lower.
The later SOHC4 forks have a "piston" attached to the lower with the stop working against it - a bolt in the centre of the axle clamp attaches the piston, the spring comes out the top and pushes that piston from above. Removing the bolt lets you pull the unit apart, exposing the seal for some prying to remove it.
The CB77 forks do not work like that. The seal has to come out first so you can't get anything in there to pry on it.
So the lower should come off freely once the seal is removed. Maybe your seal is just so stuck that popping the lower against it can't dislodge it? Heating the area around the seal may help get it free?

[Mr. Mike]

I’m not sure if you’ve got your forks apart yet, but as suggested, the 305 Forum has some terrific members. I’d recommend Ed Moore aka LOUDMOUSE. This guy is very knowledgeable and will even post his phone number for you and talk you through any issues you might have with your vintage CA, CB, CL Honda.
You can PM him through the site or search his name in posts and you might find his number, and just call. He’s in TX.

[MCRider]

Thanks for all the replies! I will note the referrals and leads for future reference.

We let the legs set with 3-1 oil in the seal cavity. We then heated the legs with a torch in the seal area, and the tube popped out of the leg just like the early CB750. The pop is created by the release of the seal which comes out with the tube.

Or I should say, the early CB750 is like the late CB77!. The fork leg dampers and bushings are just like the pre K2 CB750. the only difference is the leg assembly carries the spring on the outside of the tube/leg assy as the diameter is too small for an internal spring.

But, once we heated it up, they popped apart after just a couple of tries!

The circlip on the seal is the only thing keeping them together. The seal was probably adhering to the leg from age, but the heat broke the bond.