Motorcycle Repair: 305 Dream year and key, drive sprocket, shaft assemblies

Question
Can you advise how/where to get a key for mid 60's Dream with number on key clyinder of T4729.  Also, engine no. is CA77E  317865 but I have not yet looked for frame no.--can you tell me model year or approximate?  Also, any tricks to fix a shift shaft with damaged splines--looks like they used vise grips after splines started to strip. I would rather not try to replace--not a gifted mechanic.
Thanks

Answer
Louis,  The engine number indicates a 1963 model CA77. The frame number is on the left side, down behind the engine on the frame, where the footpeg bracket mount bolts to the frame. The chassis number will probably show CA78-3XXXXXX numbers. Frame and engine numbers should be within a few hundred numbers of each other, if they are the original pairing from the factory.

"T" series keys can often be matched by a competent locksmith. Remove the ignition switch, once you have taken the headlight out and take the lock to a locksmith. Alternately, www.hondakeys.com may have something for you. Ebay sellers often have common keys that are pre-cut. Search EBAY for "pre-cut Honda key"

The shift shaft replacement is not real easy, but can be done with the engine in the chassis. The job requires removal of the left muffler, footpeg and clutch cover (after you drain the oil). After that, the front crankshaft nut lockwasher tabs need to be bent back, the nut loosened either with the correct 4 pin tool or a blunt chisel and hammer. Pay attention to the order of the nut, lockwasher, cone washer and oil filter drive sprocket on the crankshaft.

Remove the clutch pressure plate with 4 bolts, then the plate sets, and inner which is held in with a snap ring. The clutch outer, primary chain and front sprocket must come off as a unit. Once the clutch basket is out of the way, the shift shaft just unplugs and comes right out. There are two different series of shift shaft assemblies, depending on your engine number. They changed the part in 1964, so you will need the earlier spindle, which is part number 24610-259-020. http://www.cmsnl.com/honda-ca77-dream-touring-305-usa_model992/partslist/E07.htm...

Crude repairs can be affected by either carefully drilling the shift lever and shaft, but using a bolt or pin generally only lasts for a short while, before loosening. I have seen the shifters heli-arced to the end of the shaft, as well, but you have to cut/grind them off when proper repairs are made in the future.

I have comprehensive restoration/repair guides on CD available for Dream owners.

Bill Silver
www.vintagehonda.com