Flat Tracker Honda Benly CD200 Twin Carb Conversion Project

[Tubbs]

Hi all
Heres my Honda Benly CD200 Twin Carb Conversion Project
This started out as a cd125 benly single carb parallel twin .When I bought it
it had been neglected for several years the orignal engine had been replaced with a CB125TD twin carb 180 degree motor the air filters (S&Bs) were squashed against the frame as there were clearance issues and it still had the original tin ware
So after making angled filter manifolds,seat ,side panels (compacting the wiring and electronics so they would fit ) fitting a smaller headlight and fork clamps and modifying the speedo bracket so as to fit a tacho. And after polish
and paint work touch up she ended up as in the photo.
I then bought a 200 motor on ebay For £29 rebuilt the top end rebore & pistons resurfaced cam and followers lapped the valves and replaced a bent valve smoothed exhaust and inlet tracts matched up the twin carb manifolds from the cb125td these are a direct fit but i wanted to make sure
there were no steps .I polished the casings and fiited the new motor after
altering the wiring and electronic components to 6v points set up.Fitted the twin carbs from the cb125td Cut the original down pipes and fitted them with campbell type up swept trumpet silencers
After playing about with carb settings got her running smoothly(stationary)
She sounds just like a mini bonneville 650.
I new carburation would need sorting and after riding as there was a flat
spot . It was now summer, and holiday time, camping so took the bike with us in the back the van as she ran fine on lower throtle openings
And if got the chance and found a suitable long hill would try the plug chop
method to try and sort the carburation.
First trip out on holiday after about 5 miles the bike got stuck in top and wouldn' t come out got here back to the camp in top. Never had a problem with honda gearbox before thats why i had not done a full rebuild .after taking off the engine casing found it was not an accessible selection problem and i would have to strip the motor right down to fix the gearbox
Finally got round to doing this last week where found the problem the motor had been stripped by somebody else in the past who had put a thrust washer in the wrong position this combined with too much end float on the
lay shaft had let this "floating washer" drop into recess on the lay shaft jamming the dogs on a gear and lock it in top.
As i had it apart i decided to see if it was possible to fit the 5 speed box
from cb125td and found it is possible by using a combination of the shafts
from both boxes one of these will require a small amount of machining the other a spacer (Which i have made).I decided to put the bike back on the road with the 4 speed box and do the 5 speed conversion at a later date when i have a modified Shaft
Any way bike is up and running now and am waiting for the snow to go to
take her to tog hill to try and sort the carburration so any knowledge or pointers on my set upwould be very help full
Will post pic of how the bike looks now soon
Cheers
Tubbs

[Drake]

Sacrilage to do that to a gentlemans touring machine
____________________
was: derbi senda, aprilia sx125, nsr250 mc16, cagiva mito, cb600 hornet now: mk1 bandit, KR1S, landrover series 3 light weight 2.5 petrol, 5speed box

[Moxey]

This is the bike I wish the CB 250 Nighthawk was, Benly is a much better looking machine IMO and don't they have a kickstart?
____________________
Current: 02 FZS 1000 & 91 Royal Enfield Bullet 350 Some Bike Pics...
'I was too busy paying attention to pay attention'

[pepperami]

[Tubbs]

In My Opinion the benly in standard form is pug Ugly
And looks much better customised,The fact that it has wire wheels helps (has your nighthawk have them} and a
kick start I ve taken the starter and blanked off the casing on mine
as to loose weight (also lost more weight as it now has a tiny battery}
Mind You i would'nt mind a Night Hawk 234cc 5 speed engine.as it
would drop straight in and i reckon could be converted to kickstart
using benly parts
cheers
Tubbs
____________________
Old New Rocker

[hmmmnz]

looks ace, keep the pics coming
____________________
the humans are dead
I kick arse for the lord
Wiring Diagrams BIDNIP it bitches

[Moxey]

Personally think Benly is a really nice looking bike in standard, not too sure as a cafe racer have to see how it turns out.

The 250 engine is pretty much a bored out CD 200 to it's limit of 234cc so should drop in easily enough I think, they lack a kickstart but the internals are their if I recall, if you were to fit a Benly casing with kickstart assembly it should work.

The 250 Nighthawk is a pretty ugly machine it has weird cruiser ergonomics ,though comfy I dislike it, and alloy wheels. IMO would much rather a Benly over it for normal riding position mainly and looks secondly.
____________________
Current: 02 FZS 1000 & 91 Royal Enfield Bullet 350 Some Bike Pics...
'I was too busy paying attention to pay attention'