CB200 Build

I picked up a 1976 CB200, non runner but more or less complete that I will be attempting to fettle into a presentable Cafe Racer. After a lot of build reading and image browsing I think I have the final vision but after reading Spidermans CB200 build diary and some of the comments I have decided to make sure that I get the engine right before I concentrate on anything else and as such she is now stripped to the frame with the barrels in for a rebore and the head in for a helicoil to remove the broken spark plug and sheared off easy out!! I am hoping that I can then rebuild with new pistons and reseated valves and get it soda blasted as a complete unit rather than a complete strip down. I'll then remove and plug the starter motor and get to polishing the cases and rocker cover and fit some shiny new nuts and bolts. I guess then I move onto the wheels, polish the rims and respoke (not sure where to source spokes from yet) and rebuild the forks and fit new shocks and then take on the frame, which I am really looking forward to with grinder and Mig in hand!!

I'll keep the post up to date and welcome any comments or suggestions.

Cheers
S
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That looks like fun! Good luck with the build, and piccies, piccies, piccies, they're worth a thousand words!

Keep us posted looks like a real good project

all the best Jon

Progress so far has been steady, the engine has been completely stripped, the barrels rebored and the broken plug thread helicoiled. The starter has been removed and an engineer is fabricating a suitable plug. All pretty straight forward once I managed to remove the oil filter and fabricate a tool to remove the lock nut behind the filter. I must say a big thankyou to my impact driver as I dread to think the problems that I would have got into without it. All engine parts have now been soda blasted and I am really looking forward to the results when I collect on Monday. All gaskets and O rings have been delivered by Mr Silver ready for the rebuild next week and Ebay produced a set suitably sized barrels, pins and clips for £25!! I also purchased a Haynes Manual which I must say was a complete waste of money and hasn't helped, it'll be back on ebay next week!!



With the engine away I have turned my attention to a few other bits and bobs and started having a few problems. The swing arm as the bolt was and is still siezed in the frame and swing arm. So I cut it out and now while I have at last removed the swing arm from the frame I still have the bolt sections, bushes and spacers stuck. I can only think that I am going to see if I can find a press that will do the job, should be OK on the swing arm but not sure about the frame. Watch this space. Once removed I'll have to hope that I can rescue the spacers and look at replacing the bushes with brass.



Next on to the forks, which strip down no problem until I tried to remove the cup that sits over the top of the botton section. These cups are not available, so I am loath to cut them off, but really need them off to replace the fork oil seals, polish the stantions and send to chrome. They are totally seized and they wont budge, think I need to fashion some sort of puller, but just such a small space to work with. Post some picture tomorrow.

Carbs are stripped and cleaned and gasket sets ordered for both from Mr S along with set for the fuel filter and a set of shocks.

So far so good.

Cheers
S

Where are you Slippery? I have a set of 3-leg presses which might just remove your siezed/cut bolts rather than going to an engineering shop. If you're close enough I can possibly drop them off on my travels. Paul

Hi Paul, that is a really kind offer but I think that my being in Bournemouth puts us almost as far away as possible!!!

Actually bud, i was in Poole three weeks ago and Bristol/Clifton the week before that. But yes, practicalities mean it's probably going to be a month at least before I'm back in your neck o' the woods.

A thought, try heating the outer with a blow torch, then use a suitable sized drift (such as a socket) slghtly smaller than the diameter of the hole, preferably over an open vise or similar, and give it a good welt with a lump hammer.

After spending a while with a can of carb cleaner I then decided to start giving my carbs a bit of a polish. Life after all would be dull without Autosol.

Taken a while but I think it was worth it.

And then I paid a visit to the Soda Blaster to collect my parts, need to decide now how to finish the engine, I was considering painting the head and barrels, but think I will leave as it and have a go with the mop on the rocker cover, and side casings. Then the rebuild can commence.








Cheers
S

So I'm not going to win any prizes for the fastest of builds but I'm still plodding along.






















Next I am going to have a go at the reverse electroloysis and see if it really removes the rust from the tank.

Go on Slippery, that much polishing, you're just addicted to the smell of Autosol! Looking good bud, keep it up

looking sweet
got a good contact for tank cleaning if needed ,can post pics of what ive had done in the past

Looking good I'm building a cb200 café as well, you've bought the same bars as me great minds and all that.

Cheers guys. More time and a little more progress. Would be grateful for tank cleaning contacts. The bars are good value as I found 31mm was pretty hard to find unless you want to pay big bucks. First bars they sent were too big but they changed no problem and refunded my postage.

I realised the error of my ways and had to split the cases again to locate the cam chain.

And back together again

A bit more spit and polish


Putting the lid on. Dont worry I do have some countersunk allen bolts on order.




Had this plug made up £15

Back to the frame and cracking out the mig for a bit of spluttering






Fitting the tank


custom brackets from Ikea

Fortunately my slightly off drilled holes will be covered

Mock up and seat fitting next. Just need to have a ponder. I need make some brackets to support the seat unit but I need to work out how to hinge it or some quick release system.

Some proper hard work gone it to the build, fair play, lookin real cool

Gettting the Mig out for some bracketry




Slight redesign to the rear


Quite happy with the lines


Tacking on the new hangers for the rearsets, complete with the first holes I have ever tapped. Dont worry these will be tigged by a professional.


A bit more bling


Nice rear sets

that is so looking good

Still plodding along finished the frame at last so offer for blasting and powder

and here we have gloss black and no grit or powder in the threads.

more presents

swing arm and engine brackets

new bushes

more new bushes

had to paint the spacers

Back end together

On to the front. Tapered roller bearings me thinks


front end mock up awaiting new headlight brakets


And now for the lump

need and few fresh engine bolts and then on to the electrics.

I have a few decisions still to make.
Indicators or not?
Number plate location?
Fonts fender or not?
Gaiters or not?
and of course do I try and polish the headers or wrap them, I am very undecided on wrapping.
Hope you enjoy the pictures.
Cheers