The not-so-rare '77 CB200 build

flyswat2006

Been Around the Block

• Mar 25, 2012

• #1

Here is my '77 CB200 cafe racer build. I got the bike for free from a co-worker. It has been held up in his mom's shed for an undetermined number of years. I know it was dumped into a swamp at some point. Luckily swamps are soft so the damage was minimal. After I cleaned off a good layer of oil and sawdust I managed to get it running. I actually commuted on it for three months. Then in November I started the cafe project. My plans were as follows:

Fiber Glass Cafe seat
Clip ons
Rear sets
HID head light
Chop fender
Mikuni Carbs
Replace mufflers
Paint everything
Lithium Battery

This is what it looked like after I cleaned it up and road it for a while. Looks nice but from the crash there are plenty of bent parts and dents.

 

flyswat2006

Been Around the Block

• Mar 25, 2012

• #2

Here is work I did to mount the seat I got from Speedmotoco for $170 shipped. I picked it because it was narrow and would cover up the ugly frame these bikes are know for. I also made a tray for the Lithium battery. And the tail light, new shocks, and the weld job I did to cover the ugly gas tank mounting bracket.

Here is the 4s1p lithium battery I got from emissions-free.com for $50 shipped. It should be able to turn over anything up to 600cc. It weighs nothing compared to the original Lead-acid and it doesn't need to be tended over the winter.

The head light I made from a cheap 4x4 lamp and HID lamp from ebay. A bit of a hack job but looks good if you don't look too close. I'm just a little concerned about keeping the moisture out.

 

RENO.HOOLIGAN

Active Member

• Mar 25, 2012

• #3

Damn good pickup, the headlight looks good. How much did you end up spending total for the headlight?

 

flyswat2006

Been Around the Block

• Mar 25, 2012

• #4

RENO.HOOLIGAN said:

Damn good pickup, the headlight looks good. How much did you end up spending total for the headlight?

Click to expand...

Think it was $12 for the 4x4 lamp and $80 for the HID lamp. So, ya, kind of pricy but 100x better than the original.

 

flyswat2006

Been Around the Block

• Mar 25, 2012

• #5

Here she is with the seat, bars, light, exhaust, rearsets, chopped and lowered fender.....

Adding the rearsets were a bitch. Found these on ebay for a $110. Regret buying them since the pegs are too small and not being universal made them difficult to make work. The exhaust is in the way so I had to install them much higher than I had planned.
http://i1157.photobucket.com/albums/p595/djryanrhymes/CB200T/P3040121.jpg

I like how the brake turned out. Kind of over kill but I had to use the materials available.

 

flyswat2006

Been Around the Block

• Mar 25, 2012

• #6

Made a seat pan out of a piece of PVC I got from the local plastics shop. Just cut it to shape and used a heat gun to bend it.

I used foam kneeling mats for the seat pad.

Kind of thick but since the rear sets are so high I thought it might be better this way.

 

flyswat2006

Been Around the Block

• Mar 25, 2012

• #7

Lowered my gages and cleaned it up with some pieces of old towel rack.

 

flyswat2006

Been Around the Block

• Mar 25, 2012

• #8

Here she is all primed up.

 

flyswat2006

Been Around the Block

• Mar 26, 2012

• #9

Here is my makeshift paint booth. I used plastic from my Halloween setup, hence the radio active symbol and blood spatter.

This was a pain in the ass but it's turning out great.

 

scottyknows50

New Member

• Mar 26, 2012

• #10

Impressive so far. I may have to get one of those batteries.

 

xruze56

Been Around the Block

• Mar 26, 2012

• #11

wow great work. curious question where did you get that bracket from on the speed moto site?

 

flyswat2006

Been Around the Block

• Mar 26, 2012

• #12

xruze56 said:

wow great work. curious question where did you get that bracket from on the speed moto site?

Click to expand...

Just the seat came from speedmoto. Brackets I made.

 

xruze56

Been Around the Block

• Mar 26, 2012

• #13

oh alright gatcha. yah i need a cutting torch so i can start working on my damn bracket

 

milehighcj360t

for your health, dummy.

DTT BOTM WINNER

• Mar 26, 2012

• #14

you should consider cutting the bottom rim of the seat so it matches up with the tank...it looks funny sitting below the tank IMO. Other than that, looks awesome. What color are you painting everything?

 

sxecafe

You think the Carpet Pissers did this?

• Mar 26, 2012

• #15

looking good so far.

 

flyswat2006

Been Around the Block

• Mar 26, 2012

• #16

milehigh said:

you should consider cutting the bottom rim of the seat so it matches up with the tank...it looks funny sitting below the tank IMO. Other than that, looks awesome. What color are you painting everything?

Click to expand...

The frame under the seat is really ugly - formed metal and lots of holes. I chose that seat specifically to cover it.
Paint will be orange similar to the motor.

 

WNTITAL

Been Around the Block

• Mar 26, 2012

• #17

I like the paintjob on the motor. I know what you mean by PITA! Nice job keep the updates coming.

 

flyswat2006

Been Around the Block

• Mar 30, 2012

• #18

Frame and parts are painted. Just piecing things back together.

Started painting the tank and seat.

 

flyswat2006

Been Around the Block

• Apr 6, 2012

• #19

Got my seat back from the upholstery shop. Sweet for $30. Total cost for the seat was $75.

Just layed down the clear.

 

Salty_Cafe_801

slow and low...

• Apr 6, 2012

• #20

Adding the rearsets were a bitch. Found these on ebay for a $110. Regret buying them since the pegs are too small and not being universal made them difficult to make work. The exhaust is in the way so I had to install them much higher than I had planned.

That still looks awesome for being a PITA. LOL