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Honda C77 User Manual

Honda C77
91 pages
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Technical Books
Christchurch
20
WINDMILL
CENTRE
RICCARTON
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Honda C77 Specifications

General IconGeneral
Engine ConfigurationParallel Twin
Displacement305 cc
Compression Ratio8.5:1
Transmission4-speed
Fuel SystemCarburetor
Front SuspensionTelescopic Fork
Seat Height780 mm
Weight150 kg
Dry Weight140 kg
Final DriveChain
Frame TypeSteel
Fuel Capacity12 liters
Bore x Stroke60 mm x 54 mm
Rear SuspensionSwingarm
BrakesDrum

Summary

MOTOR MANUAL

SHOP MANUAL

Manual for Honda models C72/C77, CS72/CS77, CB72/CB77.

PREFACE

Preface

Introduction to the shop manual, its purpose, and scope.

MAINTENANCE

STANDARDS

Technical specifications and dimensions for maintenance.

DISASSEMBLY & ASSEMBLY

ENGINE (C72·77) Procedures

Procedures for engine disassembly and assembly for C72/C77 models.

ENGINE (CB7277) Procedures

Procedures for engine disassembly and assembly for CB72/CB77 models.

FRAME (CB72·77) Procedures

Procedures for frame disassembly and assembly for CB72/CB77 models.

Cylinder Disassembly and Assembly

Detailed procedures for cylinder disassembly and assembly.

L. Cover Disassembly and Assembly

Procedures for left cover disassembly and assembly.

R. Cover Disassembly and Assembly

Procedures for right cover disassembly and assembly.

Mission (Crank) Disassembly and Assembly

Procedures for transmission (crank) disassembly and assembly.

Cylinder Head Disassembly and Assembly

Procedures for cylinder head disassembly and assembly.

Oil Pump Disassembly and Assembly

Procedures for oil pump disassembly and assembly.

Rear Fork Disassembly and Assembly

Procedures for rear fork disassembly and assembly.

Front Fork Disassembly and Assembly

Procedures for front fork disassembly and assembly.

Cylinder (CB72/77) Disassembly and Assembly

Procedures for cylinder disassembly and assembly for CB72/77 models.

Rear Fork (CB72/77) Disassembly and Assembly

Procedures for rear fork disassembly and assembly for CB72/77 models.

Front fork (CB72/77) Disassembly and Assembly

Procedures for front fork disassembly and assembly for CB72/77 models.

Front fork comp. Front fender

Procedures for front fork assembly and front fender.

CONSTRUCTION

POINTS OF CONSTRUCTIONAL DIFFERENCE BETWEEN HONDA 250, 300 MODEL C72, 77 AND CB72, 77.

Comparison of constructional features between Honda 250/300 models.

ELECTRIC EQUIPMENT

Ignition system

Information on the ignition system components: coil, magneto, contact breaker, spark plug.

Electric power generator

Details on electric power generation system (AC Generator, DC Dynamo).

Rectifier

Information on the rectifier component (Selenium rectifier).

Battery

Details on the battery system and its maintenance.

TROUBLE SHOOTING

MAINTENANCE STANDARDS, C72·77

EXPLANATION

Explanation of terms like Maintenance Items, Standard Value, Repairing Limit, Remarks, and Unit in Chart.

Standard Value

Defines standard size and size-limit after assembly or adjustment.

Repairing Limit

Defines unusable wear limit of parts requiring correction or replacement.

MAINTENANCE STANDARDS (Model C72)

1. GENERAL PERFORMANCE

General performance data including compression pressure, fuel consumption, and max speed.

2. ENGINE

Details regarding the engine and its components.

A. Cylinder, Cylinder Head

Specifications for cylinder, cylinder head, and related components.

B. Crank Shaft (Piston, Connecting Rod)

C. Cam Timing and Valve Mechanism

D. Upper Crank Case

E. Clutch L. Crank Case Cover

F. Transmission

G. Magneto, Contact Point

H. Oil Pump Oil Separator

I. Kick R. Crank Case Cover

J. Under Crank Case and Change

3. FRAME

A. Handle

Specifications for the handle, throttle, and levers.

B. Front Cushion

Specifications for the front suspension components.

C. Front Fork Steering Fuel Tank

D. Frame Body

E. Saddle Stand

F. Rear Fork Chain Case

G. Rear Cushion

H. Front Wheel

I. Rear Wheel

K. Electric Equipment

MAINTENANCE STANDARDS (Model CB72, CB77)

1. GENERAL PERFORMANCE

General performance data including compression pressure, fuel consumption, and max speed.

2. ENGINE

Details regarding the engine and its components.

A. Cylinder, Cylinder Head

Specifications for cylinder, cylinder head, and related components.

B. Crank Shaft, Connecting Rod, Piston

C. Cam Shaft Valve Cam Chain

D. Upper Under Crank Case

E. Clutch Crank Case Cover L/H

F. Transmission

G. Gear Change

H. Kick Crank Case Cover R/H

I. Oil Pump, Oil Filter

J. A C Dynamo Starting Motor

K. Contact breaker

L. Carburettor

3. FRAME BLOCK

A. Handle

Specifications for the handle, throttle, and levers.

B. Front Cushion

Specifications for the front suspension components.

C. Steering Stem, Front Fender

D. Fuel Tank

E. Frame Body

F. Stand

G. Rear Fork, Rear Fender

H. Rear Cushion

I. Front Wheel

J. Rear Wheel

L. Front fork comp. Front fender

B. Cylinder

1. Condenser

Details on the condenser component.

2. Head cover

Procedure for head cover disassembly and assembly.

3. Cam chain tensioner

Procedure for cam chain tensioner adjustment.

4. Sparking plug

Procedure for sparking plug installation.

C. L. Cover

1. L. cover Packing

Procedure for left cover disassembly and assembly.

2. Oil filter

Procedure for oil filter disassembly and assembly.

D. R. Cover

1. Starting motor cable

Procedure for starting motor cable disassembly.

2. Starting motor R. L. side cover

Procedure for starting motor and side cover disassembly.

E. Mission (Crank)

1. Upper crank case setting nut

Procedure for upper crank case disassembly.

2. Under crank case setting nut & bolt

Procedure for under crank case disassembly.

F. Cylinder Head

1. Cylinder head cap

Procedure for cylinder head cap removal.

2. Contact breaker

Procedure for contact breaker disassembly.

3. R.L. cylinder head side cover

Procedure for cylinder head side cover disassembly.

G. Oil Pump

1. Oil pump strainer

Procedure for oil pump strainer disassembly.

2. Oil pump packing A

Procedure for oil pump packing disassembly.

3. Snap ring

Procedure for snap ring removal.

A. Rear Fork

1. Rear brake wire comp.

Procedure for rear brake wire disassembly.

2. Rear brake stopper arm

Procedure for rear brake stopper arm disassembly.

B. Front Fork

1. Head light

Procedure for head light disassembly.

2. Wiring

Procedure for wiring disassembly.

B. Cylinder

1. Carburetter

Procedure for carburettor disassembly.

2. Cylinder head cover

Procedure for cylinder head cover disassembly.

A. Rear Fork

3. Cotter Pin

Procedure for cotter pin removal.

4. Rear wheel axle

Procedure for rear wheel axle disassembly.

B. Front fork

5. Brake wire

Procedure for brake wire disassembly.

6. Front brake stopper arm

Procedure for front brake stopper arm disassembly.

10. Front fork comp. Front fender

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