rare Honda CL200 transformation to tracker/scrambler/bratstyle

mannydantyla

New Member
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:
 

mannydantyla

New Member
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.


buffing off the polish:


Then new tires. They're Shinko 244 duel sport.


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.


Then used bondo and spot putty on the outside surface:


Then paint. Found some dupli-color paint at autozone that was almost a perfect match. You like the new grills too? 8)


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.






 

mannydantyla

New Member
New tail light and turn signals. In this pics you can see where I'm planning to chop the fender:


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!


Put it where I wanted, drew the line, masked off the chrome, and used my dremel cutting wheel. It was easy.



Now to install the new handlebars.

Removing the original ones was a pain because the wires for all the controls ran through them.


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.


And cut "hockey rinks" in the new bars for the wires to go through, and drilled holes for the mounting pegs for the levers.


Put on the new grips (oem style) and that was it!
 

mannydantyla

New Member
Thinking about making a custom seat and lowing the forks an inch or two. But for now I'm happy with it!





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

 

1sttimer

Active Member
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
 

irk miller

You've been mostly-dead all day.
DTT BOTM WINNER
Love the bike. I've always wanted one. Now you've made me want one even more.
 

mannydantyla

New Member
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:




1sttimer said:
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.
 

i.holmes

New Member
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.
 

mannydantyla

New Member
i.holmes said:
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??
 

i.holmes

New Member
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.
 

mannydantyla

New Member
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

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/34205d1394330740-engine-bogs-under-load-poor-compression-too-rich-mixture-dsc_6137.jpg
 

teazer

Well-Known Member
DTT BOTM WINNER
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
 

mannydantyla

New Member
teazer said:
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.



What do you think? Another option is Jet Hot, not sure about that either.
 
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