1977 Honda CB200

[Oldgrumpy]

Having enjoyed reading other board members rebuild projects thought I'd have a go.

https://i232.photobucket.com/albums/ee135/warsteiner_yzf/IMG_0032.jpg

Here we go, a project I picked up a while ago, a Honda CB200 twin - ok not what ideally wanted which was a CB175 like I had in the late 70's but they're rare and cost big bucks.



So, don't let the pic fool you it's a bit ropey, both mudguards are rotten, the rear shocks were mingin' and the exhausts look like they've made from bits from a hoover, the seat's ripped and to be quite frank it's a rust bucket, but all there.

It was easy to get running on the kickstart but the electric start was knackered, turned out when I opened up the motor the crank seal on the generator side had let go and somehow the crancase oil had worked its way into the starter motor.

Anyway left it in the garage for a bit and picked up bits here and there on Ebay and just got started the other week with nitromors, sandblaster, wet'n'dry and elbow grease.

Hope others are interested in old Jap iron - I'll keep a regular update on progress - or lack of if it all goes horribly wrong
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Fuel injection? Nah - carburretors - It's the way ahead - an condensers, points ......drones on

[CHR15]

[Frost]

Remember we don't just want pics of what you have finished, we want to see how shit it start off, and how you progress

[Freaky_1]

[27cows]

I used to have one of these in blue. Not seen one in years. Mine had weird steering issues that I was never able to fully sort.
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The RXS100: vehicle of choice for Chuck Norris

[pepperami]

Lots of before-during-after pictures please.
tell us about every problem you come across and how you solved it.... with pics please
pictures of any special tools you had to use or make to get the job done please.

looks like a little honey
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I am the sum total of my own existence, what went before makes me who I am now!

[Oldgrumpy]

Thanks for the replies. As requested here's a pic of the stripped down frame prior to cleaning up - ye gods what a mess, but it's solid and salvageable.

https://i232.photobucket.com/albums/ee135/warsteiner_yzf/Frame0.jpg



Swinging arm had still to be removed - resisted all efforts including heat, large hammer, soaking with diesel even a piece of scaffolding pipe levering the wrench wouldn't shift it - final solution was to cut it out which meant losing the pivot bolt.

The frame is now hanging in the garage being painted. but here's a pic of it primed

https://i232.photobucket.com/albums/ee135/warsteiner_yzf/Frame1.jpg


Other horrors emerged as it came to bits-

1. One of the fork stanchions is so badly pitted it's useless.

2. The centre stand pivot which the rear brake pedal is mounted on was seized - hacksaw time again.

3. The tank is solid but rusty inside - might get it coated or just clean as best I can.

4. I said the rear shocks were mingin' and have decided they've had it and have been binned.

5. All the indicator stems have been badly painted silver - need stripping and refinishing.

6. The clutch is stuck solid - needs rebuilding.

7. The rear carrier is knackered and has binned.

BONUS pic of err-um absolutely wrecked mudguards

https://i232.photobucket.com/albums/ee135/warsteiner_yzf/Mguards1.jpg

Loads of othor minor niggles - enough to keep me going!

My plan now is to tidy up the garage and go through all the spares I've accumulated and work out what I still need.

NOTE I have no intention of building a pristine restored machine- it's all to easy to throw money at a project - everything usable will be used - it's going to be a practical runaround fun bike (with a bit of luck).
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Fuel injection? Nah - carburretors - It's the way ahead - an condensers, points ......drones on

[UnspeedySam]

Looks like a cool project. I want to do something similar with my RXS when I have another bike to use while it's out of service.
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Riding: BMW R1150RT `02 bought mildly crashed
Fixing: Also the BMW as I get less broken bits
Gone: ZZR600 '00, TRX850 '97, RXS100 '93, JS125-6B '07, BMW R1100RS '93, Kawasaki ZX-6R-J2 '01, Honda Bros NT400 NC25 '88

[bornleader]

Good project, I was looking into buying one of these after I passed my test in the seventies, but didn't.

[pepperami]

[Oldgrumpy]

Update

The frame and swinging arm have been painted (aerosols)and having got my swinging arm pivot bushes - 4 off - from David Silver (£25 incl delivery) I pressed them into place using a vice and a couple of blocks of wood. Luckily the steel pivot sleeves although not A1 are serviceable - a good job really even Silver's can't get them, I would have to have got an engineering shop to knock a couple up. Withe the pivot itself torqued up there appears to be no play so pretty pleased with that.

https://i232.photobucket.com/albums/ee135/warsteiner_yzf/Frame02.jpg

https://i232.photobucket.com/albums/ee135/warsteiner_yzf/swingarm.jpg

Now it's onto more reassembly - the rear shocks I got from Ebay for £15 - original Showa and are very clean.
I have also bolted on a rear mudguard, also from Ebay, that set me back £60 but is well worth it - it's super clean, I believe the seller imports used parts from America.


https://i232.photobucket.com/albums/ee135/warsteiner_yzf/assembly.jpg

The front mudguard may be more of a problem, they REALLY are rare, but I may have a solution a mate gave me an old mudguard off a Honda CB250 (G5?) and it is about the right size - my plan is to cut off the mounting stay and Replace it with the stay off my knackered CB200 mudguard- will it work ? Dunno yet!!!

The rear grabrail was ok, just needed a polish - just light pitting.

I have also had a go at cleaning up the wheels - the spokes are rusted to hell. I started by rubbing them with steel wool soaked in distilled vinegar then moved onto coarse wet'n'dry paper and solvol and finshed off cleaning up the spoke nipples with a sand blaster - not perfect but it'll do. NOTE this is a "before" pic

https://i232.photobucket.com/albums/ee135/warsteiner_yzf/wheel.jpg

I'm now cleaning up the fork yokes and intend bolting on the front end today - but it's hot so I may end up swilling a few tinnies instead !!
____________________
Fuel injection? Nah - carburretors - It's the way ahead - an condensers, points ......drones on

[pepperami]

more please
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I am the sum total of my own existence, what went before makes me who I am now!

[Freaky_1]

[pepperami]

Thinking about the spokes!.

What I did with mine on an old GT250 was similar to what you have done.
I then lacquered them once they were shiny.
was`nt the best solution, but it did keep them servicable for a few years and kept a bit of the rust at bay.
____________________
I am the sum total of my own existence, what went before makes me who I am now!