Honda CD200 Benly Project

[Aff]

Final engine mount painted:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0103_zps03617b84.jpg

Tried to get Halfrauds to mix me some paint for the fork covers, etc. But apparently it wasn't on their system so they couldn't mix it. I will have to try and find it online.

In case anyone is interested it's Honda Paint Code: PB-7C, Candy Sword Blue.

So far I've only managed to find it online at $60 a can, and I don't want to pay that.

Hopefully tomorrow I will be able to find all the lost fasteners and get the bike to look like a bike again.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

Progress!

Finally managed to source the engine bolts that I had misplaced.

So stuck the engine back in the frame.

https://i1135.photobucket.com/albums/m637/Biles/20130805_154336_zps49eff47b.jpg

Forks on for some stability:

https://i1135.photobucket.com/albums/m637/Biles/20130805_154342_zpse6559c7e.jpg

Carb back on:

https://i1135.photobucket.com/albums/m637/Biles/20130805_154347_zpsd8885b74.jpg

Defiantly more bikeish now, wish I'd taken more pictures, its been a year since I stripped it down now and having trouble remembering where everything goes. There is also very little documentation about this bike out there.

https://i1135.photobucket.com/albums/m637/Biles/20130805_172344_zpsc2fdbc07.jpg

Stuck the whole ignition system loosely on the bike, so hopefully tomorrow I can start it up and see if the rebuilt engine runs, it does turn nice an smoothly though.

https://i1135.photobucket.com/albums/m637/Biles/20130805_183011_zps6d066e01.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Shaft]

https://www.rsbikepaint.com/en-gb/shop-paints.php?colourscheme=4462&6728=on
____________________
Things get better with age; I'm close to being magnificent........
20 RE Interceptor, 83 Z1100A3, 83 GS650 Katana
WooHoo, I'm a Man Point Millionaire! https://www.bikechatforums.com/viewtopic.php?t=234035

[Aff]

[Aff]

Awww.

https://i1135.photobucket.com/albums/m637/Biles/b0aaeee1-3ccf-421a-84c9-f198f3acdf02_zpsff3a746b.jpg

https://i1135.photobucket.com/albums/m637/Biles/20130809_152550_zpsa9cccd97.jpg

https://i1135.photobucket.com/albums/m637/Biles/20130809_152229_zpsc8f2de9e.jpg

https://i1135.photobucket.com/albums/m637/Biles/20130809_152723_zps8444a04a.jpg

So probably explains the no start, I think what I may have done was accidentally put the donor engines pistons and rings in the old engine (valve clearances and timing spot on BTW).

Anyway onwards and upwards, lets do it all again (sorry for the blurriness, think I got oil on the lens):

Rockers out:

https://i1135.photobucket.com/albums/m637/Biles/20130809_162551_zps9f4c5db8.jpg

Camshaft out:

https://i1135.photobucket.com/albums/m637/Biles/20130809_163732_zps346a8a3f.jpg

Thought I would be able to get the studs out and not have to drop the engine, but they weren't budging, so engine out:

https://i1135.photobucket.com/albums/m637/Biles/20130809_165250_zps05fd2618.jpg

Head off:

https://i1135.photobucket.com/albums/m637/Biles/20130809_175627_zps21c1f829.jpg

Pistons out:

https://i1135.photobucket.com/albums/m637/Biles/20130809_180456_zps98b80185.jpg

Now seeing as the pistons look fine and the original engine was running fine I was just going to get new rings, but I cant find anything anywhere also all the piston kits have just got 2 compression rings where as the OEM pistons have 2 compression rings and an oil scraper, see below:

https://i1135.photobucket.com/albums/m637/Biles/20130809_180449_zps3d1ebf92.jpg

If anyone can link me to where I can buy replacements I will be grateful, Wemoto only have the copy 2 ring pistons and DS has nothing.

Cheers.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

Have decided it's probably a good idea to use the old head, as I know that was running relatively well, also there are a couple of broken fins on the new head that I didn't notice before.

My ghetto home-made valve spring compressor.

https://i1135.photobucket.com/albums/m637/Biles/20130810_163808_zps397ee105.jpg

Valves out, waiting for new valve seals to arrive and I will lap and reinstall them.

https://i1135.photobucket.com/albums/m637/Biles/20130810_163816_zpsddce7c2f.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

OK, I've found the P/N for the rings:

13011-418-003

Superseded by:

13011-KB4-305

But everything I find is ridiculously priced (about £35 a set).
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

Tomorrow there shall be progress.

https://i1135.photobucket.com/albums/m637/Biles/20130816_194923_zps657493b6.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

So turns out Mr Muscle oven cleaner is very good at getting carbon off.
Head and pistons cleaned up:

https://i1135.photobucket.com/albums/m637/Biles/20130817_113724_zpsac5a4074.jpg

Rings on:

https://i1135.photobucket.com/albums/m637/Biles/20130817_115727_zps5ae2bf77.jpg

Valves lapped:

https://i1135.photobucket.com/albums/m637/Biles/20130817_123005_zpsb37eb544.jpg

Seals in:

https://i1135.photobucket.com/albums/m637/Biles/20130817_123655_zps18ee41ea.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

More progress.

Valve springs back in:

https://i1135.photobucket.com/albums/m637/Biles/20130818_111309_zps1d3c4177.jpg

Cylinders honed, the camera doesn't really show it very well, but it came out nice, a good 45° cross hatch.

https://i1135.photobucket.com/albums/m637/Biles/20130818_114303_zps189e8ed9.jpg
https://i1135.photobucket.com/albums/m637/Biles/20130818_114307_zpsc90da247.jpg

Pistons etc back in, huge pain in the ass without a second set of hands.

https://i1135.photobucket.com/albums/m637/Biles/20130818_130226_zps8d373c9a.jpg

Head on and cams in. Having the chain run down the middle makes it very awkward setting the timing.

https://i1135.photobucket.com/albums/m637/Biles/20130818_141333_zps1ff3dbf5.jpg

Rockers on and valve clearances set:

https://i1135.photobucket.com/albums/m637/Biles/20130818_142444_zps8e883c98.jpg

Engine back in the frame, also a huge pain in the ass without a second set of hands:

https://i1135.photobucket.com/albums/m637/Biles/20130818_152556_zpsa007a0c5.jpg

And then it came to start it....and nothing.

Spent a few batteries worth of electricity trying to diagnose, it would start for a few seconds on carb cleaner, so I stripped the carbs down.

Turned out to be a stuck float, so sorted that and stuck the carb back on the bike.

Bodged on the Fireblades battery using cable ties and had another go.



https://s1135.photobucket.com/user/Biles/media/20130818_171523_zps337d303f.mp4.html

Still need to play about with the carb a bit, but at least it runs now.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

OK had some time, so a bit of progress:

Decided to tackle the wiring, was a bit of a state, consisting of about 10% actual wiring and 90% Scotch Locks and electrical tape.

Electrical tape is a pet hate, it just turns to dust and leaves the wires a sticky mess:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0365_zpsd3a0a4a7.jpg

The rest of the wiring just looked like this:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0367_zps47698954.jpg

All stripped down and tidied up with self amalgamating tape:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0366_zps7977a022.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0368_zpsd52404de.jpg

Also replaced the old glass type fuse.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0362_zps9ced7989.jpg

With a newer blade type:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0363_zps7f61d84e.jpg

Also managed to get these cheap on eBay:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0361_zpsc72501e3.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0371_zps7f2e51bc.jpg

Look the part and should work better than the old ones, seeing as they had no oil in them.

New sprockets too:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0370_zps80c24c7c.jpg


Decided I would attack the wheel, not been looking forward to these, still haven't found a good way of removing all the rust and paint from spoked wheels. Best I've found so far is a dremel with a few hundred 1/4" sanding drums.

Got one of the wheels prepped and primed though.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0374_zps2b6fc256.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0375_zpsb6ef615d.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[beardface]

Nice, can't wait to see it all re-assembled! Below is a picture if my old 1970 CD175, the most reliable and smooth bike I have ever owned.

https://i257.photobucket.com/albums/hh215/rokone_2008/front-4.jpg
____________________
www.soundcloud.com/bodren

[Aff]

OK, so it's been 6 months, I think the primer should be dry now.

Got both the wheels painted:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0639_zps6831d0e6.jpg

The drums looked pretty tatty but cleaned up OK so wont be bothering to paint them.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/20140614_101910_zpsa6wzo5je.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/20140614_103733_zpsm2tjdley.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

Stuck some Metzeler ME22's on the wheels:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/20140615_112159_zps0jcggogc.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[pepperami]

MOAR NOW!
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[_Troy_]

Haven't looked through this thread before, and saw the date of the first post and was hoping to read a project from start to finish.

But then I realised I have been in your garage recently, and there are many bits in many boxes
____________________
Current bike: ZX6R J1
Previous bikes: CLR 125 | GS500 | ZX6R G2 | SV650

[Aff]

[Aff]

Bit more progress.

New rear sprocket:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0659_zps62f24d86.jpg

A chassis that rolls:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0662_zps56cef2b0.jpg

Looks like a may have pinched the tube putting the front tyre on.

Stuck the battery and tank on:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0663_zpsba01f794.jpg

Was having fuelling issues again when I tried to start it. The float was gummed up again, took it off and blasted it out and all is good.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0664_zps4d1df082.jpg

It now starts and runs quite nicely:

https://www.youtube.com/watch?v=msAjEyOZkps&feature=youtu.be

Also riveted the VIN plate back on.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0665_zps6fd3f6f4.jpg
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

Had a spare hour. Got some little jobs done, not much in the way of pictures.

Got the centre stand, rear brake and front brake all connected:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0207_zpsa346760c.jpg

Also stuck a chain on it:

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0209_zpscd947889.jpg

Will update with more in 6-8 months.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[pepperami]

MOAR NOW!

Don`t make me wait
____________________
I am the sum total of my own existence, what went before makes me who I am now!

[-Monty-]

[Shreeve]

Give in to the peer pressure and update more regularly!
____________________
Current: Suzuki GSX650F (2010), Suzuki GSXR1000 K7, Suzuki GS250T (1980) currently restoring: Clicky.
Previous: Honda CBF 125 (2011), Suzuki GSXR750 K4

[Moo.]

MOAR!
____________________
A2 Passed 18/6/10

[Bubbs]

Glad I didn't see this thread when it first started - I'd be disappoint.

Looking good though.. only 3-4 more years and she'll be ready
____________________
Life begins at the end of your comfort zone.

[Robzki]

Enjoyed the read, thank you 👍