Category Archives: Projects

Fix it, install it, break it down. Our projects in progress and instruc­tions for some things we’ve fig­ured out how to do.

Getting It Home

We have friends, very help­ful friends. The kind who have bots that cruise Craigslist for inter­est­ing motor­cy­cles for sale. And then post the best ones to mail­ing lists with a plain­tive “Who’s going to buy this one?” append­ed. Yeah, those guys. So on a not so sun­ny Sun­day we went off to look at a Hon­da 305 Dream.

This is what we found in Sil­vana. It’s com­plete except for mir­rors, a bro­ken tail light lens, and a cou­ple of miss­ing badges. The pipes are wrong. The motor doesn’t turn, the rear wheel is frozen but the trans­mis­sion snicks nice­ly and the body parts are all present and account­ed for with no major dents or holes. Oh, and it came with a love­ly lit­tle flower on the han­dle bars.

It doesn't have mirrors but there's a nice flower on the handle bars.

The new toy. 1966 Hon­da 305 Dream.

So we got it loaded up on the back of the Defend­er. It got com­pli­cat­ed because we didn’t think about the non-fold­ing foot pegs. We had it half way up there and real­ized that we had to get the spare tire off of the back door. (But I love the hitch rail car­ri­er. No trail­er to back up next to this guy’s boat.)

just a little tighter

Loaded up and almost ready to trav­el.

Once home we had tha prob­lem of how to get a non-rolling bike off the rail and into the shop. Uh, yeah, we’ve got a trac­tor for that.

tractors - not just for manure!

This is how we (don’t) roll down here on the farm.

And there it is. Tucked in between the cut-offs box and the com­pres­sor wait­ing it’s turn.

new home

Warm and dry.

The engine num­ber is: CA 77E — 1004102. The body num­ber is: CA78 1004074. I tried to get a pic­ture  but there’s no way with­out start­ing dis­as­sem­bly and we can’t do that just yet.

CA 77E - 1004102

Engine Num­ber (roll-over)

There’s a lit­tle water here.


Bare­ly 5k on the clock.

Bonus: Jim got it on the lift Mon­day night. But it’s going to have to wait a week or two for any more atten­tion. The “Great Rover Heater Motor Fail­ure Right Before Win­ter Starts of 2011” has to be fixed first.

waiting patiently

On the Lift

Part way through disassembly…

Well, I am part way through the dis­as­se­bly of our Hon­da 305 Dream project. Some has gpne pret­ty smooth­ly, a few bits are being obsti­nate. One of the easy parts was the cool alu­mini­um carb cov­er:

the carb cov­er is intact and in decent shape.

the right hand engine cov­er is being obsti­nate, the screws are rust­ed and only 4 have bro­ken loose so far, and i’m puttin’ the hurt on my impact dri­ver bit. I did get the alter­na­tor cov­er off, and what i found wasn’t real­ly good news:

uh-oh, i think we’ve had some water in here…

After I saw this, I did drain the oil and there was near­ly a quart in the engine, so it hasn’t been *emp­ty* for all these years, but it might not be re-build­able. soon, i’ll get the engine out and apart and we’ll see.

Here’s the pile of parts that have come off so far:

head­ers, seat, bat­tery hold­er, etc. not in per­fect shape, but usable.


So the chal­lenges right now are: how to get the frozen rear brake back­ing plate out of the rear hub, and how to get the foot­pegs off so i can take the engine out of the frame. Sug­ges­tions are wel­come, as always!



The engine begins to reveal it’s secrets

Well, I now have the engine out of the frame, and the cylin­der head and both side cas­es off. The news isn’t all bad. Most of the engine looks in fine shape inter­nal­ly, as you can see here:

obvi­ous­ly, this engine has been sealed up, and has the low mileage indi­cat­ed by the odome­ter (5129).




There was a lit­tle bit of sludge in the bot­tom of the side case on this side, but noth­ing dra­mat­ic. remov­ing the cylin­der head, how­ev­er, revealed a whole ‘nuther pic­ture:

obvi­ous­ly, the left cylin­der (on the right in this pic­ture) had some water in it for a while.




and look­ing at the cylin­der head, we can see why:

if you expand the pic­ture and look close­ly, you’ll see that the exhaust valve on the left cylin­der (again, right side in the pic­ture) is slight­ly open. so water vapor got in through the exhaust pipe, con­densed into a pud­dle, which then evap­o­rat­ed and rust­ed the cylin­der.


still, noth­ing here looks unsal­vagable. the cylin­ders are cur­rent­ly soak­ing in Kroil, hope­ful­ly, i can beat the pis­tons out pret­ty soon and see what kind of shape the cylin­der walls will clean up into.


thanks for read­ing. more as i dis­cov­er it!



Nearly ready for paint, prep, and parts-gathering

Well, with a few days off over the hol­days, I’ve got­ten the 305 Dream to the point where I don’t believe there is any­thing unsal­vagable here, and it won’t take an exor­bi­tant amount of mon­ey to put this thing back on the road in nice shape. The last few hours of work have been to get the frame stripped of all oth­er parts, so I can start clean­ing it and get­ting it ready for blast­ing and paint. Here’s the parts that will be going out for paint, plus the tank, once it’s clean inside.

swingarm, front fend­er, frame

front fork, side­stand and foot­peg mount

I have a large list of parts I need (sent off to cyclepsy­cho to see what he might have), and a cou­ple of unsolved prob­lems. I am as yet, unable to remove the steer­ing head nut from the top of the stem. I think I man­aged to move it with a pipewrench, so I gave it anoth­er soak­ing in Kroil and will try again lat­er. I still have one pis­ton with the rings firm­ly stuck in their grooves. and last­ly, I broke off a screw in the bot­tom of the fork (it holds a chrome cov­er in place over the front swing­ing arm and shock). I then tried to drill it out, but the drill wan­dered off course, so now I have a hole through the screw at an angle, and it goes through the threads part­way down. Grrrr… I’ll have to spend some qual­i­ty time with the dremel tool and see how bad off the threads are when I’m done.

the screw that got the best of me that day.



But over­all, pret­ty smooth­ly so far. at this point, it’s about get­ting the frame and paint­ed parts cleaned and repaint­ed, clean­ing out the bot­tom end of the motor, hav­ing the cylin­ders honed (bored if they don’t clean up well at std. size), and the start clean­ing and re-assem­bling.

mean­while, it all waits in a tidy pile. More pics lat­er.