Honda CD200 Benly Project

[Aff]

Hi All

A couple of months ago I got the er6f back on the road after I decided it would be a good idea to 'park' it into a wall at 40mph. I enjoyed having something mechanical to work on in my free time and found myself craving a new project as soon as I had nothing left to do on the bike.

I spent the next couple of months looking for something suitable. Something simple and easy to work on so that I could use it to get some experience.

Eventually i found a little Honda CD about 30 miles from me. The ad said it was in ridable condition (he was using it each day to go to work) but had a crack in the engine case and was leaking oil. I thought this was a perfect excuse to strip it down and replace/clean everything.

When I got the there the bike looked in reasonably good nick with just alot of grime and oil and some surface rust. It kicked over first time, i paid the bloke 190 notes and started the ride home.

It bogged down at anything below 1/4 throttle so I imagine the carb is full of shit. other than that it rode quite nice, pulls well up to 70 and topped out at an indicated 85. Clutch slipped quite badly so I will be replacing that as well. Gearbox also felt a bit clunky, but I'm not sure whether that was the clutch or that the nature of the box, I will see when i take it apart.

When I got it home and stuck it in the garage I saw the extent of the oil leak (I thought the guy was exaggerating when he said "I seem to be putting in as much oil as I do petrol") so I drained the oil to save my garage floor (came out nice and amber ) and took some pics.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0653.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0654.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0655.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0656.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0659.jpg
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Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Aff]

Took the carb off and stripped it down, was full of crap as expected, the petrol in the float bowl looked more like hot chocolate. (forgot to take pics unfortunately ).

Here it is in bits though, the benly has a single carb.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0660.jpg

Then i gave it a quick clean and polish and stuck it back together, i will be replacing the rusty screws when i can be bothered to find some at work.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0661.jpg

Quick question, should i be using any kind of sealant on the gaskets? or do I put them in dry? (Carb and Engine BTW)
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Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[paddlesat16]

Hi

The gaskets are dry

Regards
____________________
I once saw a bloke shagging a donkey.... in Saudi arabia. Theory Test Passed 26/10/09 Mod 1 Passed 26/4/10, Mod 2 Passed 7/6/10 Current Bikes Suzuki GSX1400 K5, Aprillia Pegaso 650, Suzuki DR350T.

[Aff]

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

[Aff]

Dropped the engine out the bike after much swearing, WD-40, sweat, blood and hammering of an impact driver (best purchase ever). Engine is nice and light so just stuck a ratchet strap around it to take the weight and manoeuvred it out of the frame.

As stood there basking in my glory i noticed something silver still in the frame, I went to investigate and found an engine mount that had decided it wanted to go solo.

So it turns out the small crack in the engine wasn't so small. I suppose it explains the oil consumption/expulsion.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0663.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0664.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0665.jpg

So I will be looking for a donor engine or some new cases. I cant find a parts diagram anywhere (if someone could find one I would be eternally grateful) and its hard looking for a part when you don't know what its called.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Teflon-Mike]

Err, yeah, that looks rather NASTY!
Co-Incidentally, I may be able to help you out with replacement cases... I have a CD200 motor, I bought to knock down, for a Super-Dream project..... just been loath to do so as its a runner as it stands... but we can talk about that later.

Engine mounts dont just 'break'!

I would be rather more worried about what has CAUSED that boss to fracture AND accross BOTH cases.

Best case, numpty prebiouse owner 'dropped' the engine, with it out of the frame, and caused a crack that has grown.

Worst case, and possibly the more likely is that the bike had a hard impact that has twisted the frame., putting that boss under stress causing it to fatigue fracture.

Curiouse though; engine is semi-stressed in the frame, and the rear mountings are the major load bearing points.

Front down tube, simply completes the triangulation from the head stock.

Quiet common for the front mounting bracket to be left 'loose' or have a bolt out, and then the frame flexes, and that COULD cause undue stress on the rear mounts, BUT, not where I would expect damage to occur, unless the whole engine has been left shaking itself to bits, with ALL the bolts undone!

You ARE unfortunately not too nearby, or I'd suggest hauling it over here to have a shuftie, see how my engine lines up in the frame.

Meanwhile, I'd get some bits of string, chalk, and a dry patio and see if I could do some alignment checks... get the bodywork stripped back, look for stress witnesses in the frame, that kind of thing.

No point getting another engine, or rebuilding an engine to find it wont fit, because the frame is bent; bike rides like a camel, because its not straight, and or misaligned mountings simply do to another what hath been done to that!
____________________
My Webby'Tef's-tQ, loads of stuff about my bikes, my Land-Rovers, and the stuff I do with them!
Current Bikes:'Honda VF1000F' ;'CB750F2N' ;'CB125TD ( 6 3 of em!)'; 'Montesa Cota 248'. Learner FAQ's:= 'U want to Ride a Motorbike! Where Do U start?'

[Shaft]

I was wondering if someone has dropped the motor before and undone everything, leaving that bolt until last, then the engine has tried to 'swing' around that point and cracked the case.
____________________
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

[chrysanthy]

[Aff]

Thanks for the reply Mike,

I did check the frame when i first got it and all seemed good (will probably do a more detailed check now i have everything off it).

Like i said i rode it back and it was riding absolutly fine (or as well as it can with no rear dampening)

The bloke i bought it off said that it was dropped at about 15 mph in the wet about a year ago and slid quite a way down the road (didnt hit anything though), you can see the marks from this on the inspection cover. He said that after this, there was a very slight oil leak. It passed its MOT about a month after the crash. After the MOT he rode it 40 miles a day 5 days a week and he said the leak got progressivly worse.

Due to the nature of the engine its very viby so i just assumed that it started as a crack near a mounting point and worked its way around untill eventually it broke itself away. (maybe even my ham fisted engine removal technique finished the job the engine started)

I will definatly be chacking it again but im quite confident that the frame is OK
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[mattb_uk]

Great little project, the kind of thing I am looking to dable in, though Im looking for an old Suzuki A100 (first bike I ever owned) of similar.

Can I ask what you used to clean the carb? it looks like new!

Cheers,

Matt

[Aff]

[mattb_uk]

As simple as that!

Cheers,

Matt

[Aff]

Done another check on the frame and all seems fine, so im guessing that the guys story is true .

Started stripping the engine down. Was fighting me all the way with all forms of reluctant screws. Once again thank god for the impact driver.

Rocker cover off.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0666.jpg

Rockers out.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0668.jpg

Cams out.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0669.jpg

Head off.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0670.jpg

All looks fairly good to me, looks like it was running very rich as everything is very coked up and the spark plugs were very sooty. Anyone got any tips on cleaning?

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0674.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0672.jpg

Clutch cover off and clutch out.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0676.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0677.jpg

Clutch was slipping quite badly but the friction plates don't look too worn. I'm trying to find the measurements for the springs with no luck, does anyone know a bike with the same clutch or have access to the haynes?. Or does anyone know if it could have been something else making the clutch slip?

Cheers,

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

[paddlesat16]

The old owner might have been using synthetic car oil, which will make the clutch slip??

Regards
____________________
I once saw a bloke shagging a donkey.... in Saudi arabia. Theory Test Passed 26/10/09 Mod 1 Passed 26/4/10, Mod 2 Passed 7/6/10 Current Bikes Suzuki GSX1400 K5, Aprillia Pegaso 650, Suzuki DR350T.

[Aff]

Managed to get some more time to work on the bike today.

I think I may have found some replacement crank cases, just waiting for the breakers to get back to me to see if the engine number prefixes match.

Finally managed to get the flywheel off, think I may have broken something but I couldn’t see anything broken on initial inspection, will have to look closer tomorrow.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0698.jpg

Oil pump out.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0699.jpg

Kick start out.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0700.jpg

Gear selector shaft (is it called that??) out.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0701.jpg

Took 4 years to spit the cases due to more rusty dowels.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0703.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0704.jpg

Gear selectors and gears out.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0705.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0707.jpg

Crank shaft out.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0708.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0709.jpg

Everything looks in pretty good nick so far. Need to go buy some more paraffin and clean it all up.

Next will be taking all the bearings out and measuring them up so that I can buy some replacements.
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Usher4566]

Quick question for ya when you did clutch did it have a castle nut or a clip?
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New cd200 benly owner

[Usher4566]

Quick question for ya when you did clutch did it have a castle nut or a clip?
____________________
New cd200 benly owner

[Aff]

Pretty sure it was a circlip, my memory is terrible though
____________________
Current Bikes:Honda 929RR Fireblade, Honda CD200 Benly (Project), Stomp Z2 140
Electric Bike Project

[Usher4566]

Ok many thanks for reply
____________________
New cd200 benly owner

[Aff]

Ok its been bloody ages, but my collar bone is finally back in 1, almost straight, piece. Took a couple of weeks to get the er6f back on the road, but now i can concentrate on the CD.

Whilst I was stuck at home for a month I was able to source a donor engine and got a courier to pick it up.

Last weekend i stripped it all down and rebuilt the original engine back up with the new crank cases. Unfortunately i didnt have a camera with me so havent got any photos.
It all went very smoothly though, as the donor engine had much less rust. If you read my previous posts backwards it will give you an idea of how it went back together.


Today i carried on stripping the frame down.

Took all the wiring loom off, its a bit of a mess, its probably about 40% choc blocks and 60% electrical tape.
The wiring in the headlight seemed to be the home to about ten thousand baby spiders, all nice and crispy from the heat of the light/lack of flies living in the housing.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMAG0016.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMAG0017.jpg

I will come back to and tidy the wiring up later on.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0769.jpg

Started taking the rear end apart, the rear shocks are completly shot, will have to buy some new ones. Also they were held on by 2 different nuts and an assortment of about 15 different washers...

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0766.jpg

Wheel isnt as bad as i though it was.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0765.jpg

Drum brake is a bit grubby and needs new shoes.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0768.jpg

Does this sprocket need replacing? Im replacing the chain anyway.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0767.jpg

Swinging arm out, was worried it would be seized, but apart from some odd sized nuts it came off fine.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0763.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0764.jpg

The swinging arm was caked in about a half inch thick layer of oil/mud/general road crap.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMAG0026.jpg

Spent hours trying to clean it off, eventually got it all off and about 50% of the paint fell off with it, there was a fair amount of surface rust but nothing that looked serious.

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0770.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0771.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0772.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0773.jpg

https://i1135.photobucket.com/albums/m637/Biles/CD200%20Project/IMG_0774.jpg


I will strip the rest of the paint off then respray it when we get some better weather. Then ill have to do the same to the frame ...

Has anyone got any tips on getting the crap off a bit quicker? I was using parafin and a stiff brush.

Cheers!

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

[mccluskeyd]

Well done with your efforts so far !

I had a CD200 for a few years, and found it probably the best "round the town" commuter that I have ever owned.

I only sold it to make way for more junk / projects, so probably should have kept hold of it.

As for getting rid of old road grime & caked on dirt ; yes parafin or old petrol and an old pot scrubbing brush is fine. If you are a little more impatient, a jet washer is even better, but then you have to contend with water in places that you never really intended.

The wire brush attachments for your drill are great for getting rid of blistered & rusty paint etc. I see that the one in your picture is the cone type. Lidl quite often do packs of them cheaply with the flat type ones which are even better.

All the best with it,

David.

[Aff]

[nfo]

Nice work. Headlamp full of bodges and crispy spiders is just like my CB125

I see that the CD200 has the same tank mounting arrangement as my bike - what's the trick to getting the lip on the tank into the rear rubber mount?
____________________
Mar's Law: Everything is linear if plotted log-log with a fat magic marker.
1975 CB125S 'repair and tidy up' project thread here...

[paddlesat16]

Scrap the sprockets, nice new shiney new ones when you do the chain

Regards
____________________
I once saw a bloke shagging a donkey.... in Saudi arabia. Theory Test Passed 26/10/09 Mod 1 Passed 26/4/10, Mod 2 Passed 7/6/10 Current Bikes Suzuki GSX1400 K5, Aprillia Pegaso 650, Suzuki DR350T.

[Aff]