Motorcycle Repair: fuel line arrangement., honda cb77, fuel line fittings


Question
Good afternoon Bill,
I am trying to restore a 1967 Honda CB77 and am in the process of replacing the petcock that came with the bike, which was not the correct petcock. I have managed to obtain an old petcock and have rebuilt it to as new condition and now I need to know how the fuel lines attach. I am making an assumption that the two barbs on the side of the petcock each feed a carburettor, is that a good assumption? If that is correct then I need to know the configuration of the hoses from the third barb, which I am also making an assumption that it is the reserve barb and also there must be some 'Tee's' involved somewhere along the line. Can you explain either verbally or with a diagram how the hoses should be configured correctly and if possible the lengths of these hoses.
Best regards and thanks in advance.

Answer
Mel, If your bike is actually a late model 1967-ish version, then your fuel tank does not have the "crossover" tube which was used on the pre-1967 models. If this is the case, then the petcock you have is for the early model fuel tank. You can just use a short piece of hose with a plug in the end or a fuel-resistant rubber cap to block off the lateral fuel fitting.

The two downward facing fittings go to each carburetor, as you surmised. I suggest angling the fuel line fittings on the carb body to about 45 degrees from horizontal to facilitate a nice curve of the fuel lines to each petcock fitting.

See http://www.cmsnl.com/honda-cb77-super-hawk-305-usa_model1001/partslist/F++05.htm for the part numbers and illustrations.

Bill Silver
www.vintagehonda.com

PS I have restoration guide CD available. Info at my website.