QuestionHi Bill. I'm about to overhaul the carb on my 1966 CA77. It looks almost impossible to remove the carb without having to drop the engine from the frame. i.e it's burried up inside the frame and even with the tank off there's no access to the top of the carb. Is there an easy way to remove it?
AnswerPaul, it will come off w/o engine removal. With the carb covers off, remove the fuel line from the carburetor, then remove the fuel line fitting if it is the screw on type.
The clamp on the air filter tube needs to be loosened and then the air filter connector boot pulled back slightly and then push it up away from the carb inlet.Take off both of the 10mm wrench-sized nuts from the carb flange.
Probably best to remove the battery, to access the plate next to the air filter and loosen the air filter retainer nut. The air filter bolt goes all the way through the frame and anchors under the rectifier on the right side.
Removing the left side nut allows the filter to move around more freely. The air filter tube connection at the carburetor is often damaged from fuel, softening the rubber and tearing it at that junction, so be as careful as you can with the tube at the carb connection.
Pull the carb back off the studs and down a little so you can reach up and unscrew the carb top from the body.
Be careful, when reassembling the carb top, that the slide is properly installed, so that the slot in the slide aligns with the index inside the carb slide throat. Once you have the top installed again, twist the throttle and release it to ensure that it is returning properly. You should hear a distintive clunk when the slide returns to the bottom of the carburetor. Reassemble in the reverse of disassembly.
Do not overtighten the carb flange nuts, as it can cause the flange to warp the body and seize the slide. Check the flange for warpage and use a large file to straighten out the flange before installation. Float level is 26.5mm.
I have restoration guides available for this model.
Bill Silver www.vintagehonda.com
