New 73 CB200 Caff Build
- Thread starter hecklejk
- Start date
New 73 CB200 Caff Build ~ Down for the count
Well it looks like the build has hit a bit of a snag! I screwed up and forgot to check the oil after I had done all of the work on the bike, and as a result the engine is locked up! Unfortunately This build is going to have to be put off for a while, with all the stress of planning my wedding and more than 60% of my budget going to the wedding as well I just dont have the time nor the money to continue this build at the moment.
On a brighter note, I did find some new jugs and pistons off of a bike that only had 6k miles on it on ebay that I was able to steel for $45 shipped!! Once I have the funds I want to get the cylinders bored/honed 1mm oversized so that I can put in oversized pistons but that will come much later down the road.
This little snag does give me the time to do all the things that I was putting off until next winter though, which I look at being a good thing. Some of the things that I have planned for the rest of this build include:
1. Taking the engine apart and cleaning the shizz out of it
2. Replacing all of the case screws with hex head ones
3. Painting the engine (black with yellow accents) ~ probably going to paint all of the screws and bolts yellow!
4. Cleaning, sanding and painting the frame
5. Rebuilding the Wiring harness
6. Replacing the Headlight Ears
7. Removing the Tachometer and fabricating a new mount for the Speedometer
8. Repainting the Tank (to include filling in the Emblem mounts and painting new emblems on)
9. Cleaning and lubing the chain ~ if I dont just replace it
10. Removing the Kick stand, this bike is so very light that putting it on the center stand is EASY!!
Those are just the big things that are planned for the bike now that it will be down for a few more months. All of these things require minimal $$, most of them I already have everything I need to complete them I have just put them off!
I will still be checking in with the progress of these projects, just thought I would let you guys know the status!!
Cheers,
Kevin
Well it looks like the build has hit a bit of a snag! I screwed up and forgot to check the oil after I had done all of the work on the bike, and as a result the engine is locked up! Unfortunately This build is going to have to be put off for a while, with all the stress of planning my wedding and more than 60% of my budget going to the wedding as well I just dont have the time nor the money to continue this build at the moment.
On a brighter note, I did find some new jugs and pistons off of a bike that only had 6k miles on it on ebay that I was able to steel for $45 shipped!! Once I have the funds I want to get the cylinders bored/honed 1mm oversized so that I can put in oversized pistons but that will come much later down the road.
This little snag does give me the time to do all the things that I was putting off until next winter though, which I look at being a good thing. Some of the things that I have planned for the rest of this build include:
1. Taking the engine apart and cleaning the shizz out of it
2. Replacing all of the case screws with hex head ones
3. Painting the engine (black with yellow accents) ~ probably going to paint all of the screws and bolts yellow!
4. Cleaning, sanding and painting the frame
5. Rebuilding the Wiring harness
6. Replacing the Headlight Ears
7. Removing the Tachometer and fabricating a new mount for the Speedometer
8. Repainting the Tank (to include filling in the Emblem mounts and painting new emblems on)
9. Cleaning and lubing the chain ~ if I dont just replace it
10. Removing the Kick stand, this bike is so very light that putting it on the center stand is EASY!!
Those are just the big things that are planned for the bike now that it will be down for a few more months. All of these things require minimal $$, most of them I already have everything I need to complete them I have just put them off!
I will still be checking in with the progress of these projects, just thought I would let you guys know the status!!
Cheers,
Kevin
Well, it has been a while since I last posted of course it has also been a while since I did any work on the bike! Got home from work last night and decided it was time to get going again, in a matter of about 1 1/2 hours I got the motor out and ready for rebuild. I have a few other things to do before I get started on the engine, such as cleaning the frame up and painting it / taking the wheels off the bike to get the new tires mounted / painting the new engine parts and polishing the case / and cleaning up the wiring harness. Still got a ways to go, but I got the motor pulled and that was really the thing that was holding me back. I will post some pics of the engine rebuild and frame clean up process.
Cheers,
Kevin
Cheers,
Kevin
andrew embassy
Been Around the Block
hecklejk said:
Keep at it man, summer's right around the corner!
Re: New 73 CB200 Caff Build ~ Engine Rebuild!!
Well, I spent about 2 hours out in the shed yesterday working on the motor... specifically working on removing all of the stripped scews (both case screws and internal motor screws). Everything was going great until I tried to pull the 4 screws that secure the Point Base to the Head, 2 came out just fine but the other 2 already had stripped heads!!
Being that I do not own an impact driver, or a stripped screw remover I had my work cut out for me!! I grabbed my flat head screw driver bits and my 3 Lbs hammer and went to town tapping away!!! After about an hour I had the 2 stripped screws in the Points Base out, so I moved onto the Shift side engine cover which had 75% of the case screws with stripped heads. Thank god I got new Allen head bolts for the case screws!! Now I need to find 2 screws to replace the Points Base screws that I had to demolish to remove!! Can I just take the stripped ones to a local hardware store and find a similar screw?
I continued on removing things and was able to get the Right cylinder head cover off without any issues!! The next step is a bit confusing to me, I read the manual but do not understand what to do Next... any help would be greatly appreciated!! I have never rebuilt an engine before, so this might get a bit interesting!!
Cheers
Well, I spent about 2 hours out in the shed yesterday working on the motor... specifically working on removing all of the stripped scews (both case screws and internal motor screws). Everything was going great until I tried to pull the 4 screws that secure the Point Base to the Head, 2 came out just fine but the other 2 already had stripped heads!!
Being that I do not own an impact driver, or a stripped screw remover I had my work cut out for me!! I grabbed my flat head screw driver bits and my 3 Lbs hammer and went to town tapping away!!! After about an hour I had the 2 stripped screws in the Points Base out, so I moved onto the Shift side engine cover which had 75% of the case screws with stripped heads. Thank god I got new Allen head bolts for the case screws!! Now I need to find 2 screws to replace the Points Base screws that I had to demolish to remove!! Can I just take the stripped ones to a local hardware store and find a similar screw?
I continued on removing things and was able to get the Right cylinder head cover off without any issues!! The next step is a bit confusing to me, I read the manual but do not understand what to do Next... any help would be greatly appreciated!! I have never rebuilt an engine before, so this might get a bit interesting!!
Cheers
yes you can just go hit up the hardware store for the replacement... a trick that will help you get them out... take a punch and put it in the center of the screw you are try'n to extract... then SMACK it good with a hammer... this will stretch the threads of the bolt, break any loc-tite loose, and make it much easier to get out!
Did some work on the engine rebuild this weekend, mostly cleaning up the shift side engine covers since I ran into some issues getting the cam chain off (see post http://dotheton.com/index.php?topic=8542.0)so that I could get the top end apart!! spent about an hour cleaning the 30+ years of gunk off of the outside and inside of the engine cover ( GOJO scrubbing wipes are awesome for this!!!) then took some steelwool to the covers to get the residual clear coat of and to scratch the aluminum up to accept the paint. After cleaning up the covers, I applied one coat of 500 degree engine paint and I think it cam out looking pretty good. I forgot to take a before picture (which I always forget to!!) but here is the finsihed product (after 1 coat of paint)
Named the Project!
I have noticed that a lot of the projects on the forum have names, so I have decided on a name for my project. I am offically naming this build ~ "Project Bee Sting" ~ I think it fits for 2 reasons, 1. the colors I have chosen for the bike are Black/Yellow, and 2. It seems to sting me everytime I work on it (i.e. one problem after another)...
I have noticed that a lot of the projects on the forum have names, so I have decided on a name for my project. I am offically naming this build ~ "Project Bee Sting" ~ I think it fits for 2 reasons, 1. the colors I have chosen for the bike are Black/Yellow, and 2. It seems to sting me everytime I work on it (i.e. one problem after another)...
Sorry for the lack of recent replys!! May has been a really busy month for me. I have not made much progress on the bike since I still cant get the wrist pin out of the shift side piston... but thats on another post. I did have a chance to get some paint work done on the motor, here are just a few shots of what she looks like at the moment.
I guess the next step is going to be cleaning up the frame and painting it, think I am going to have to take the engine to a shop to get that stuck wristpin out....
I guess the next step is going to be cleaning up the frame and painting it, think I am going to have to take the engine to a shop to get that stuck wristpin out....
Curbcast said:
Well, it has been quite a while!! I have been really busy this summer what with getting married and all!! I have also been very frustrated with this project, and given up on it twice... I am now however back to work on the bike, and proud to report that I was finally able to get the stuck piston pin out of the connecting rod! This week I am planning on smoothing out the ridge in the connecting rod that was left from the seized piston pin. I am still looking for a gasket set on ebay, so that is really all that is holding me back on completing the motor rebuild. Once I get the bike done, it is going to have to go up for sale though... The wife and I have been talking and I think we are going to be moving to England, and the cost involved in importing this bike to the UK is astronomical... so I figure I can just sell this one and find a good runner over there.
