Cafe racer project

[Tony a]

Picked up a CD200 Benly, my intention is to turn it into a cafe racer. Have seen a few of these bikes turned into a cafe racers and thought I would like a project and turn my hand at trying to do something that I have never tried before. The bike has quite a bit of rust on the frame but it's only seems to be surface rest. Here is the start and as I progress I will update this post.

 

[Alex jb]

Good luck,
Buy a rotary wire brush for the drill and a dust mask


Sent from my iPhone using Tapatalk

 

[Hurco550]

Re: Cafe racer project

Welcome. Looks like there is plenty to keep you busy on that thing! Don't want to discourage ya, and I don't know where your abilities are, but I recommend getting that thing running to make sure it's not a dud, especially before you make your first big dime city cycles "cafe bling" order. That advice is free for you, but it cost me.... first hand experience =/ anyhow, again welcome, and good luck!

 

[Tony a]

Thanks for the advice, I already have a rotary wire attachment for my drill and I had a little test clean on the engine and I was happily surprised that it's just a build up of dust accumulated since its been parked in the garage since 1988. As for the engine, it has good compression. The frame , as far as I can see only has peeled paint and surface rust. The worst part of this bike is the electronics , that seems totally shot. I'm fortunate in the sense that I have a motor mechanic for a brother in law who has owned motorcycles and has always worked on them.

I'm going to take my time and do it right. It may take me a year or even longer but I want it to be right the first time . I have a bike I ride now so there is no hurry. And this is what I'm riding at the moment.

 

[yorkie350]

Welcome in mate, +1 with hurco ,take plenty of pics for reference as well as for your updates we all love pics here plenty of inspiration and answers too good luck mate will be following

 

[Tony a]

Will deffo be taking lots of photos, will update my post over the weekend. I'm looking to take out the engine and get started on the frame.

 

[goldy]

Best of luck with your build and please keep us posted. The CM 200 is one bloody tough little engine (my kid had one) if it comes out anything like that 125, it ought to be awesome!

 

[Tony a]

My build is a CD200 not a cm200. But I'm sure it will be a challenge .will keep you all posted.

 

[Tony a]

Well that's the air filter housing and battery box off. Having trouble with the exhaust's, the bolts fixing them to the frame are solid. Will have to buy a blow torch and try to heat them up as to break the seal that has developed. I'm going to post some pics and I would be very grateful if someone could tell me what they are. Please remember I'm not a mechanic so I'm on a very long learning curve.

 

[Tony a]

And these are the bits I'm wanting identified
A,

 

[Tony a]

B,

 

[Tony a]

C,
( I think I know what this one is but I'm not 100% sure

 

[Brent]

Hey Tony,
Top picture is the regulator, the middle the ignition coil and the bottom the signal flasher.
This site has schematics for Honda that will help with ID and assembly. http://www.houseofhondaparts.com/fiche_select1.asp?cat=Motorcycles&mfg=Honda
You should join this forum if you haven't already. http://www.hondatwins.net/index.php

 

[Tony a]

Thank you Brent, will take a look at your link. Every bit helps.

 

[Hurco550]

For seized bolts, I cannot recommend a 50/50 mix of acetone and ATF (automatic transmission fluid) highly enough. The acetone thins the ATF and allows it to creep into the threads, then evaporates leaving the lube in the threads. Drip some on the seized faster, leave it for a day, then try workout heat. It beats anything I've found that you can buy off the shelf

 

[Tony a]

Thanks hurco550, will deffo give that a go. I managed to get the right side exhaust off. Was lucky to be able to lend a snap on set from my neighbor. Going to give the other exhaust a go tomorrow.

 

[Tony a]

I have a question, are there any off the shelf wheels that will fit the CD200.

 

[Bevelheadmhr]

I have a question, are there any off the shelf wheels that will fit the CD200.

I couldn't tell you if there are, but I'd ask what it is you want to achieve by changing the wheels you have?

If the answer is because your wheels are rusty, then I'd say its likely to be cheaper to rebuild the wheels you have (new spokes, polish your hubs etc) and either buy new rims or if your rims aren't too bad, maybe paint them or powder coat them.

Mint second hand spoked wheels which may fit your bike are in demand, and wont be cheap... I'm assuming your based in the UK?

 

[Tony a]

I'm not actually looking for mint secondhand wheels, more like New retro wheels. To be honest I'm not 100% sure what I will do until I get the wheels off. I have found what looks like a reputable company that are specialist in powder coating bike frames and parts.

Have done a little bit more to the break down of my bike. Have got the wiring loom out in one piece. I was quite surprised at how naked the bike looks with out all the wiring.

 

[goldy]

It's coming right along eh? I didn't know about the CD version...had to look it up. Same engine apparently, but frankly I like the styling better than the CM models.