collapse

www.dimecitycycles.com


www.restocycle.com

www.CITYLIMITMOTO.com

www.jadusmotorcycleparts.com

www.bisonmotorsports.com

www.speedmotoco.com

www.cognitomoto.com

www.townmoto.com

www.sparckmoto.com

www.Moto-Madness.com

www.pistonsociety.com

www.steeltowngarage.com


Author Topic: rare Honda CL200 transformation to tracker/scrambler/bratstyle  (Read 14414 times)

Offline mannydantyla

  • Posts: 119
    • dannix.net
Doing it right!
« Reply #30 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.



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.



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.




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



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.



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!



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??
« Last Edit: Apr 30, 2014, 12:14:55 by mannydantyla »

Offline mannydantyla

  • Posts: 119
    • dannix.net
Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
« Reply #31 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.


Offline mannydantyla

  • Posts: 119
    • dannix.net
Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
« Reply #32 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!


Offline xb33bsa

  • Posts: 7727
Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
« Reply #33 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

Offline 1sttimer

  • Posts: 2086
Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
« Reply #34 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
1973 CB175
http://www.dotheton.com/forum/index.php?topic=53893.new#new

"There is never enough time to do it right the first time, but there is always enough time to do it over."

Offline sancho

  • Posts: 81
Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
« Reply #35 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!

Offline mannydantyla

  • Posts: 119
    • dannix.net
Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
« Reply #36 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 ;)

Offline mannydantyla

  • Posts: 119
    • dannix.net
Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
« Reply #37 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


Offline samsquantch

  • Posts: 106
Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
« Reply #38 on: Jul 23, 2014, 19:12:43 »
Very classy scrambler! Can you ride 2-up on those little guys?

Offline mannydantyla

  • Posts: 119
    • dannix.net
Re: rare Honda CL200 transformation to tracker/scrambler/bratstyle
« Reply #39 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  ???