DO THE TON

Blood Sweat Tears and Grease => Projects => Trackers => Topic started by: mannydantyla on Feb 07, 2014, 15:18:04

Title: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Feb 07, 2014, 15:18:04
What started out as a mild, stock-ish restoration of a hard-to-find 1974 Honda CL200, the project began to steer in the direction of darkness when I decided to add some bratstyle/tracker styling cues. One thing led to another, and the next thing I find myself doing is bobbing the rear fender.

For complete details and full pics, go here: http://www.hondatwins.net/forums/1-project-logs/26432-cl200-street-tracker-project.html

This is the first (running) motorcycle I've owned. I found it on craigslist and it was in pretty fair condition to begin with. Was running well but the stock air filters where crumbling apart and those had to be replaced. Then it was normal maintenance: adjust tappets, clean the centrifuge oil filter, replace leaky gaskets, etc.

As it looked when I found it:
(http://dannix.net/public/pics/cl200-build-pics/IMG_2246.JPG)

Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Feb 07, 2014, 15:30:42
Onwards!

Polished all the aluminum. Went through ~$50 in dremel tools to remove the nasty factory finish. Then hit it pretty hard with #1 steel wool. Then nevr-dull polishing compound + #0000 steel wool, then blue magic metal polish. Then a coat of turtle wax to keep them from tarnishing for a while. Will need to be applied yearly though.
(http://dannix.net/public/pics/cl200-build-pics/IMG_2987.JPG)

buffing off the polish:
(http://dannix.net/public/pics/cl200-build-pics/IMG_2998.JPG)

Then new tires. They're Shinko 244 duel sport.
(http://dannix.net/public/pics/cl200-build-pics/IMG_3008.JPG)

So the side covers where cracked, broken, and ugly. I also wanted to replace the "gills" as I call them with perforated aluminum. First I repaired the plastic side covers with plastic-weld epoxy and some fiberglass tape stuff.
(http://dannix.net/public/pics/cl200-build-pics/IMG_2463.JPG)

Then used bondo and spot putty on the outside surface:
(http://dannix.net/public/pics/cl200-build-pics/IMG_3050.JPG)

Then paint. Found some dupli-color paint at autozone that was almost a perfect match. You like the new grills too?  8)
(http://dannix.net/public/pics/cl200-build-pics/IMG_3102.JPG)

For the exhaust, I ordered some exhaust tips from ebay and made the baffles myself. The stock muffler had a giant hole in the bottom. The new pipes are about as loud, maybe louder, but the baffles to a good job of muffling the nasty high-pitched sounds.
(http://dannix.net/public/pics/cl200-build-pics/IMG_3039.JPG)

(http://dannix.net/public/pics/cl200-build-pics/IMG_3041.JPG)

(http://dannix.net/public/pics/cl200-build-pics/IMG_3113.JPG)

(http://dannix.net/public/pics/cl200-build-pics/IMG_3121.JPG)
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Feb 07, 2014, 15:58:48
New tail light and turn signals. In this pics you can see where I'm planning to chop the fender:
(http://dannix.net/public/pics/cl200-build-pics/IMG_3080.JPG)

I wanted to keep the same geometry as how the factory shaped the fender, just higher up on the bike. So I made a template. You can also see the chrome where the PO had used sandpaper to try to remove chrome pitting. That has got to go!
(http://dannix.net/public/pics/cl200-build-pics/IMG_3083.JPG)

Put it where I wanted, drew the line, masked off the chrome, and used my dremel cutting wheel. It was easy.
(http://dannix.net/public/pics/cl200-build-pics/IMG_3086.JPG)


Now to install the new handlebars.

Removing the original ones was a pain because the wires for all the controls ran through them.
(http://dannix.net/public/pics/cl200-build-pics/IMG_3091.JPG)

Here's the new bars next to old for comparison. They're "daytona bars" but are perfect for the bratstyle look. I had to cut through the old ones because the wires wouldn't come out.
(http://dannix.net/public/pics/cl200-build-pics/IMG_3093.JPG)

And cut "hockey rinks" in the new bars for the wires to go through, and drilled holes for the mounting pegs for the levers.
(http://dannix.net/public/pics/cl200-build-pics/IMG_3097.JPG)

Put on the new grips (oem style) and that was it!
(http://dannix.net/public/pics/cl200-build-pics/IMG_3138.JPG)
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Feb 07, 2014, 16:04:21
Thinking about making a custom seat and lowing the forks an inch or two. But for now I'm happy with it!

(http://dannix.net/public/pics/cl200-build-pics/IMG_3131-cropped.jpg)

(http://dannix.net/public/pics/cl200-build-pics/photo-snow-headlight.jpg)

I finished just in time for the local vintage motorcycle show. I got third place in the Japanese street division!

(http://dannix.net/public/pics/cl200-build-pics/IMG_3189.JPG)
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: chucklump on Feb 07, 2014, 20:14:38
Were do you get baffles like that?
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Feb 08, 2014, 15:40:01
Were do you get baffles like that?

I made them but you can buy some for not to much more really and just wrap them in fiberglass
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: Serial__Thrilla on Feb 08, 2014, 20:51:04
Sweet!
Title: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: 1sttimer on Feb 09, 2014, 09:49:18
How do your baffles make the exhaust sound?  I don't like the look of my stock CL muffler at all but don't want to run open if I hacked them off.  What jetting issues did you have when you hacked and added the custom baffles? 


Sent from my iPhone using Tapatalk
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: irk miller on Feb 09, 2014, 12:02:18
Love the bike.  I've always wanted one. Now you've made me want one even more. 
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Feb 09, 2014, 13:34:24
Thanks, glad you guys like it! I'm really happy with how it looks, it's the perfect bike for me. Thinking about possibly adding a custom seat. However, I really like the way the stock one looks! With the chrome buttons and strap.. If anything I'll wrap the stock seat-pan in a nice black leather and shave off some foam to lower the profile a bit. And possibly lower the forks and/or raise the rear shocks...

Lots of "inspiration" credit goes to Woody's CL350 brat tracker, 2.3efi CL360 City Scrambler, and similar. Honestly though, seeing those builds reassured and reinforced the image I had in my head for it. I'd like to do some "glamour" shots, just to appease the photog side of me, if i'm not "over it" by the time the weather improves.

Inspiration:
(http://www.dimecitycycles.com/media/catalog/category/vintage-semi-stock-motorcycle-honda-yamaha-suzuki-kawasaki-for-sale.jpg)
(http://img703.imageshack.us/img703/1162/edit1of15.jpg)
(http://www.motobuilder.com/wp-content/uploads/2010/12/woody.jpg)

How do your baffles make the exhaust sound?  I don't like the look of my stock CL muffler at all but don't want to run open if I hacked them off.  What jetting issues did you have when you hacked and added the custom baffles? 

They sound good! Loud, but without the high-pitched, slappy, nasty tones. Maybe a little bit louder than the stock muffler with big ass hole in the bottom, but better.

I'll try to post a video.
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: chucklump on Feb 13, 2014, 19:14:16
I like how the cops shinning the light at your bike.
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: shift_love on Feb 13, 2014, 19:27:03
(http://img703.imageshack.us/img703/1162/edit1of15.jpg)

I love this one, its totally rad
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: i.holmes on Feb 18, 2014, 17:03:18
I've got the same bike!! When I found mine it was in great condition and it makes me worried about cutting into it. I've had a lot of the same inspiration bikes that you've posted here. How rare are these bikes actually?

I know that I can do whatever I want since my bike is mine but everything on the bike is still original and I would hate to ruin some of the pieces since they are so nice. I do plan to change out the stock handlebars for daytonas like you did. Seat is a whole other monster. I would love a flat leather seat but they all look so uncomfortable.

(http://s1043.photobucket.com/user/sbaugz/media/DSC_0227-1.jpg.html)

I like the way your going with yours and would love to see what you do to it next.
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Feb 21, 2014, 23:30:43
I've got the same bike!! When I found mine it was in great condition and it makes me worried about cutting into it. I've had a lot of the same inspiration bikes that you've posted here. How rare are these bikes actually?

I know that I can do whatever I want since my bike is mine but everything on the bike is still original and I would hate to ruin some of the pieces since they are so nice. I do plan to change out the stock handlebars for daytonas like you did. Seat is a whole other monster. I would love a flat leather seat but they all look so uncomfortable.

I like the way your going with yours and would love to see what you do to it next.

Haha yeah, I found your build thread too. Some advice: do NOT replace the air boxes with pods, repair them if you must. Do NOT leave the petcock open for even a few minutes or gas will make it's way into the oil, which could ruin the cam, journals, and tappets. Join us at hondatwins.net, those guys are masters at diagnosing problems. Right now I'm having problems with it bogging from a stop and a weak top speed. The pod filters are a performance downgrade for sure, and the chopped exhaust shrinks the RPM range. I have a range of main jets I'm trying, just put in #93s and will test out tomorrow, but pilot jets cannot be found. If you have any questions, feel free to PM me.

And I know exactly what you mean about tearing into it. Part of me is not happy about ruining a "survivor". But another part, a much bigger part, is very happy with how it's turning out. I know I made the right choice though because every time I park and walk away, I have to look back and admire it  ;D

I'm having a custom seat created this Tuesday, so stay tuned. ;)

Oh, and I don't know HOW rare the bike is.. NO  ONE does. Honda never exposes the sales numbers for any of their models, even 40 years later. My VIN number is CL200E-1007044. 7044th one exported??
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: i.holmes on Feb 23, 2014, 10:47:33
I had a similar issue with bogging, mine was when I was at speed then after short runs it would stall. I figured out it was the bowl floats were not adjusted correctly. Easy fix, just bent the arms of the floats and tested it by turning it upside down and blowing thru the fuel line to make sure there were no leaks.

I think if I end up doing anything to mine it will just be changing the handle bars. I like the stock ones but they look so goofy.

I'll definitely be staying tuned with your build and I've checked out hondatwins a couple times just havent started on the forums over there yet.
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: Steaksauce on Feb 27, 2014, 09:32:53
Clean bike, your inspiration might have just became mine haha
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Mar 08, 2014, 23:34:57
Clean bike, your inspiration might have just became mine haha

Thanks!
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Mar 08, 2014, 23:40:03
Alright, so I had the seat re-upholstered and it looks great! The guys at The Interior Shop in Kansas City did it for $100, and I highly recommend them!

(http://www.hondatwins.net/forums/attachments/33802d1393447364-custom-seat-builder-recommendations-1921086_10153881144855254_1451054495_o.jpg)
http://www.hondatwins.net/forums/attachments/33802d1393447364-custom-seat-builder-recommendations-1921086_10153881144855254_1451054495_o.jpg

But I'm having engine issues. The right cylinder is not firing as hot as the other. Then today I discovered that the two carbs have different size pilot jets! Not sure if this is the source of the problem, but I definitely need to find some pilot jets to get them the same. But I can't find any the CB/CL200. Does anyone know where some could be found??

(http://www.hondatwins.net/forums/attachments/34206d1394330744-engine-bogs-under-load-poor-compression-too-rich-mixture-dsc_6141.jpg)
http://www.hondatwins.net/forums/attachments/34206d1394330744-engine-bogs-under-load-poor-compression-too-rich-mixture-dsc_6141.jpg

(http://www.hondatwins.net/forums/attachments/34205d1394330740-engine-bogs-under-load-poor-compression-too-rich-mixture-dsc_6137.jpg)
http://www.hondatwins.net/forums/attachments/34205d1394330740-engine-bogs-under-load-poor-compression-too-rich-mixture-dsc_6137.jpg
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: teazer on Mar 09, 2014, 01:05:05
BTW, those pilot jest are very different - not just the numbers,  but check out the air bleed holes.  The 38 will probably run leaner than the 35 because it's allowing more air in, but it may also have better atomization that the #35
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Mar 13, 2014, 01:33:31
BTW, those pilot jest are very different - not just the numbers,  but check out the air bleed holes.  The 38 will probably run leaner than the 35 because it's allowing more air in, but it may also have better atomization that the #35

Yes, yes they are. We think the #38 is stock and the #35 was added on. I have another #38 from a CL175 in the mail, should be identical to the one I have now. The CB200 comes with #88 mains and #38 pilot jets, and the CL200 has #35 and #95 jets. HOWEVER, my particular CL200 came with the jetting profile of the CB, I know this because it had #88 mains and the tuning numbers 008A is stamped on both carbs.

I can't get the idea out of my head of wrapping the headers with a titanium wrap. They're a little rusty, but not too bad. I made another mock-up, which helped me decide to keep them the way they are. Not terribly pretty chrome, but better to stay stock than ruin the headers or something.

(http://dannix.net/public/pics/cl200-build-pics/another-mockup.jpg)

What do you think? Another option is Jet Hot, not sure about that either.
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: teazer on Mar 13, 2014, 16:09:09
I'm a cheapskate and use high temperature exhaust paint or BBQ paint.  I even tried white Hi Temp ex paint once - never again.  It looked like crap after a few miles as do white frames.

I'd suggest polishing the headers with aluminum foil and chrome polish and leave it at that.
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Mar 20, 2014, 16:41:52
Got a replacement #38 pilot jet and now the two cylinders are firing the same! Both spark plugs are nice and black!! Haha, obviously they're two rich and the bike is a total slouch, but it's a step in the right direction. I have a range of main jets to "play" with.

I'm waiting for my new fancy camera to arrive in the mail so I can take some proper glamour shots, but here is a teaser until then:

(http://www.hondatwins.net/forums/attachments/34827d1395344404-cl200-street-tracker-project-2014-03-18-19.25.37.jpg)
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Apr 15, 2014, 14:47:57
Shortly after taking this picture...

(http://www.hondatwins.net/forums/attachments/35765d1396973670-cl200-street-tracker-project-dsc00447-web.jpg)

...I began hearing some SCARY sounds from the engine. At times it was a ticking from the head, other times a clanking from the crank area. So the engine must come out and be inspected.

(http://www.hondatwins.net/forums/attachments/35761d1396973340-cl200-street-tracker-project-dsc00512.jpg)

https://www.youtube.com/watch?v=yIWBSc3Nesk

(http://www.hondatwins.net/forums/attachments/35892d1397174208-cl200-street-tracker-project-hdr1-web.jpg)
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Apr 15, 2014, 14:58:29
Camshaft look great, rockers are good, journals are OK but good enough. Cam chain is immaculate, I thought maybe it would be broken.

(http://www.hondatwins.net/forums/attachments/35809d1397069596-cl200-street-tracker-project-dsc00027.jpg)

Pull the head off, and it was not pretty. VIEW DISCRETION IS ADVISED!!

(http://www.hondatwins.net/forums/attachments/35888d1397174007-cl200-street-tracker-project-dsc00126-web.jpg)
(http://www.hondatwins.net/forums/attachments/35889d1397174009-cl200-street-tracker-project-dsc00133-web.jpg)
(http://www.hondatwins.net/forums/attachments/35891d1397174010-cl200-street-tracker-project-dsc00141-web.jpg)
(http://www.hondatwins.net/forums/attachments/35890d1397174010-cl200-street-tracker-project-dsc00138-web.jpg)
(http://www.hondatwins.net/forums/attachments/35894d1397177941-cl200-street-tracker-project-dsc00149-web.jpg)

Today I ordered a used head on ebay (cheaper than having the valve seats re-cut) and new pistons. These pistons are hard to find! CMSNL has the best inventory but the highest prices. I found one +0.25mm piston+ring kit on ebay so I bought that, ordered the same piston from CMSNL, and matching rings off ebay. While I was at it, I added a bunch of oil seals the CMSNL order. It was 4am last night, I probably could have thought of a dozen more things I needed....
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: wahvtec on Apr 15, 2014, 15:25:39
woof, is that from something making its way in there and hoping around for some time?
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: teazer on Apr 17, 2014, 01:53:51
Ouch.  Any idea where the nut that was ingested came from and how it got in there?  Do you have filters on the carbs or did it run open for a bit?   I can't see any signs of a bolt thread but the indentations look like a hex nut and been in there.
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Apr 17, 2014, 12:40:17
I have no idea what happened to it, but it certainly looks like something was in there.

Considering painting the engine, thinking VHT engine enamel in cast iron color, with the side covers polished aluminum.... not sure... to paint I would have to clean it with degreaser then put in the dishwasher, then bake in the oven to remove all oils embedded in the aluminum pours (http://www.dotheton.com/forum/index.php?topic=52360.0), then media blast to remove residue, then prep with metalprep 79, then VHT self-etching primer, then paint, and then finally bake in the oven...
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: irk miller on Apr 17, 2014, 13:14:20
I have no idea what happened to it, but it certainly looks like something was in there.

Considering painting the engine, thinking VHT engine enamel in cast iron color, with the side covers polished aluminum.... not sure... to paint I would have to clean it with degreaser then put in the dishwasher, then bake in the oven to remove all oils embedded in the aluminum pours (http://www.dotheton.com/forum/index.php?topic=52360.0), then media blast to remove residue, then prep with metalprep 79, then VHT self-etching primer, then paint, and then finally bake in the over...
  That seems like overkill to me.  I understand why you want to bake the aluminum for oil, but if you're going to use phosphoric acid to etch anyway, then you could probably just soak the parts in a bath of diluted phosphoric etch, then run them through the dishwasher or soak them in a bath of water- even boil them.  Phosphoric acid, which is what Metalprep 79 is, breaks down oil and similar carbon-based materials.  It also etches the hell out of aluminum converting it into aluminum phosphate and hydrogen gas.  VHT or any other etching primer usually contains phosphoric acid and zinc.  I'm not sure it's necessary on aluminum, since you don't have to worry about rust.  Plus, I would question if it will continue to etch the aluminum.  On steel, it converts rust into ferric phosphate and water.  Then the zinc prevents further rusting.  You don't have to worry about that with aluminum.  As far as the final baking, you could also do that on the engine, but in the oven pre-assembly will certainly make it more durable. 
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mattrod68 on Apr 21, 2014, 02:52:07
here is what that titanium wrap looks like in real life, cl350 but should give you an idea


(http://i668.photobucket.com/albums/vv43/triplecrowncustoms/IMG_2205_zpsdd329a49.jpg) (http://s668.photobucket.com/user/triplecrowncustoms/media/IMG_2205_zpsdd329a49.jpg.html)

(http://i668.photobucket.com/albums/vv43/triplecrowncustoms/IMG_2207_zps5153e4c8.jpg) (http://s668.photobucket.com/user/triplecrowncustoms/media/IMG_2207_zps5153e4c8.jpg.html)

Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Apr 21, 2014, 22:20:34
here is what that titanium wrap looks like in real life, cl350 but should give you an idea

Perfect! I'll probably continue to wonder "what if??" but right now I can't spend another dime on this project. Pistons, rings, oil seals, etc where somewhere around $230, paying the machine shop $300 for a valve job and cylinders bored and honed and to sandblast everything, plus bought some hondabond and UNI filters to replace the emgo pods.

Thought you guys might like to see the innards.

(http://www.hondatwins.net/forums/attachments/36041d1397352469-cl200-street-tracker-project-dsc00181-web.jpg)
(http://www.hondatwins.net/forums/attachments/36040d1397352468-cl200-street-tracker-project-dsc00175-web.jpg)

The first thing you may be asking yourself is, why did he remove the upper crankcase and not the lower? Well, I had it upside down to remove all the bolts. Then I broke it free but left it like that last night. While I was asleep, my friend (who does know a lot about motorcycles, but not after a dozen beers) decided he'd have a look at it. I woke up with a text message from him saying he thinks I need a new piston (duh) and with the engine now flipped right side up.  I was so mad. I found a retaining ring (at first I thought it was half a piston ring) and two tiny cylinders (looks like they're for oiling the crank) at the bottom of the case. Thankfully the gasket surface doesn't look messed up.

So I just went ahead and pulled the upper crankcase off instead of the lower. BTW, I didn't need to remove the clutch, fuel pump and filter. All that needed to be done was wiggle the shifter arm out of the drum spindle thingy. It would be easier with the clutch off, especially for reassembly. I have to move gears and crank into the upper case half (after I paint it first), it would be impossible to put it back together the other way.

I also inspected the gear shifting mechanism to find out why I get the shifter stuck sometimes. The forks look good I think, but the gear selector arm (the thing with the big washer on the end) seemed a little off - the rivet was warn and the washer could sit off-axis. So I'm replacing both that and the neutral stopper arm.

You can tell from this pic that there was almost a millimeter of wiggle-room.
(http://www.hondatwins.net/forums/attachments/36094d1397436856-cl200-street-tracker-project-dsc00213-web.jpg)

no burs or flat spots in the labyrinth, and the forks where not warn looking
(http://www.hondatwins.net/forums/attachments/36092d1397436854-cl200-street-tracker-project-dsc00199-web.jpg)
(http://www.hondatwins.net/forums/attachments/36093d1397436855-cl200-street-tracker-project-dsc00207-web.jpg)
Title: Doing it right!
Post by: mannydantyla on Apr 29, 2014, 17:08:25
View the full image gallery of the engine overhaul, here: http://dannix.net/home/pictures/set/72157644033907140

Painted cylinder jugs, head, and both case halves with VHT engine enamel in the cast iron color. I think it looks great! The head and jugs where first coated with VHT self etch primer and the finish is very hard. I didn't bake in the over, either. But I didn't have the primer for the case halves, so instead a prepped with something called Alluminum Jelly, from the makers of Navel Jelly. It has phosphoric acid in it which etches the aluminum and eats away rust and organic matter (oils). The finish is pretty solid, but not likely as good as with proper primer. The case covers will all be polished aluminum.

(http://www.hondatwins.net/forums/attachments/37779d1398480574-cl200-street-tracker-project-dsc00375-web.jpg)

Time to install the pistons! They're hard to find. CMSNL has the best inventory but the highest prices. I couldn't find two matching pistons off ebay, so what I did was buy one +0.25mm and two sets of rings off ebay to save money, and one +0.25mm piston from CSMNL.

(http://www.hondatwins.net/forums/attachments/37977d1398654085-cl200-street-tracker-project-dsc00424-web.jpg)

Checked ring gap clearances first, they're good. Oiled up the rings and installed them on the piston - made sure to install in correct order and with the right-side-up indicator facing up. With the pistons somewhere after TDC (so they're coming down) and a penny wedged in the clutch/oil filter gears so they won't move, I dropped on the cylinder jugs down on them. I thought that I would have to pinch the rings with my fingers all the way (remember, this is my first time overhauling an engine) but the bottom of the cylinders sleeves are tapered I guess, so that wasn't really necessary. I just had to guide rings in (doing my best to keep them spaced 120 degrees) and give a good amount of steady forced down on the cylinders.

(http://www.hondatwins.net/forums/attachments/37978d1398654123-cl200-street-tracker-project-dsc00425-web.jpg)
(http://www.hondatwins.net/forums/attachments/37979d1398654124-cl200-street-tracker-project-dsc00429-web.jpg)

Now onto the head. The only hangup I had here was getting the chain onto the sprocket. It wouldn't go on this way:

(http://www.hondatwins.net/forums/attachments/37980d1398654144-cl200-street-tracker-project-dsc00433-web.jpg)

with the chain in the middle between the sprocket and the cam flange, I couldn't get the chain onto the sprocket because the sprocket couldn't turn. I had to slip the sprocket under the chain and then I could get it on.

(http://www.hondatwins.net/forums/attachments/37981d1398654164-cl200-street-tracker-project-dsc00434-web.jpg)

Set the timing by following the FSM. Used loc-tite on the sprocket bolts and engine oil to lube the cam up (didn't use assembly oil because I didn't want anything synthetic, but I really don't know which is best). Installed the rockers next, then the timing house and tach gear house, and then bolted on the cover!

(http://www.hondatwins.net/forums/attachments/37982d1398654710-cl200-street-tracker-project-dsc00435-web.jpg)

Done. Right? Wrong. Turns out I installed the kickstarter wrong - the "friction spring" isn't in it's grove, so it doesn't, well, it doesn't kick start the engine.  So I need to open the case back up. That's when I removed the side cover to find that the gasket had slipped out of position when I was tightening it down, and it was completely blocking an oil passageway!  So... oops??
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on May 10, 2014, 18:04:44
It's running! I'm going through this break-in procedure to seat the piston rings: http://www.ntnoa.org/enginebreakin.htm

I think oil flow is good. I finished putting the bike back together and was ready to check to see if oil was being pumped. I kicked it around 50 damn times and could see no oil on the tappets. I read about how others had this same issue and that the engine needs to be running before theres enough oil pressure to circulate the oil. So I turned on the ignition (took quite a few kicks, and will need to adjust the carbs to get it to idle) but it fired up and was running and then oil started squirting out the tappets! Woohoo!! The oil pretty much sprayed all over the front wheel, so I'm guess that it's good.

(http://www.hondatwins.net/forums/attachments/38794d1399658075-cl200-street-tracker-project-dsc00658-hdr-web.jpg)
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Jul 18, 2014, 19:02:29
sorry I haven't gotten around to posting the images until now, I've been having too much fun riding it! It's replaced my car as my daily driver for around town, and I get so many compliments wherever I go. But what matters is that I like it, and I love it! It's perfect!

Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: xb33bsa on Jul 18, 2014, 19:23:54
fantastic, bravo sir  :)
it looks way too good and is actually way too well done to fit in the bratstyle category
jmoymmv
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: 1sttimer on Jul 18, 2014, 20:08:46

fantastic, bravo sir  :)
it looks way too good and is actually way too well done to fit in the bratstyle category
jmoymmv

I agree.  Amazingly functional looking.  I'd tear that thing up on a back country road.


Sent from my iPhone using Tapatalk
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: sancho on Jul 18, 2014, 20:49:19
Wow, such a nice bike man! Thanks for the motor rebuild page. I am going to be rebuilding my cl175 this winter, your write up will definitely help! Thank!
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Jul 20, 2014, 06:47:43
Thanks for the kind words, you guys are great!

It's just been nominated for bike of the month, looking for a nice fellow to second it ;)
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Jul 23, 2014, 19:06:30
The bike has been accepted as a nominee for bike of the month!

If you like it then please vote!! -> http://www.dotheton.com/forum/index.php?topic=61599

Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: samsquantch on Jul 23, 2014, 19:12:43
Very classy scrambler! Can you ride 2-up on those little guys?
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Jul 24, 2014, 00:25:40
Very classy scrambler! Can you ride 2-up on those little guys?

Sure can!

My girlfriend loves to ride on the back (might have something to do with the vibrations  :o) but I admit that starting up a hill from a stop with 2-up is a real challenge, and I can't claim that we're under the 300 pound weight limit  ???
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: maxDTM on Aug 20, 2014, 17:37:22
Love this little scrambler. Had might vote in BOTM. Congrats on the Bike Exif feature!!

http://www.bikeexif.com/honda-cl
Title: Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
Post by: mannydantyla on Sep 15, 2014, 15:20:30
Love this little scrambler. Had might vote in BOTM. Congrats on the Bike Exif feature!!

http://www.bikeexif.com/honda-cl

Thank you! It was also shared on facebook by Iron and Air