CB200 based greenlane/cusom/thing
Discussion
Hello all,
Thought I'd chronicle my build of a little motorbike.
I bought a f
ked CB200 a couple of years ago. It's been in an accident in apparently 1982 and looks like it spent the years since then stored at the bottom of a salt mine. Whilst it was mostly complete it's everything needed work. I took it apart to try to restore, moved house, stacked up the bits and never touched it.
I was playing with the idea of doing a little greenlaning and making an off-road bike from something like a CG 125, plus my mate then decided we should try racing at the malle mille event next year, so my idea to do that became a little more than just the idle musing it had been. Looking at what was about at the very cheap end of the market were similarly fked bikes, so I thought, what the hell, let's drag it out and see if I can make some sort of functioning motorcycle out of it with very little budget. It will be "not concourse", but might be a fun wee thing to blast round the countryside on.
The pistons were seized like crazy so that was the first job.
Thought I'd chronicle my build of a little motorbike.
I bought a f
ked CB200 a couple of years ago. It's been in an accident in apparently 1982 and looks like it spent the years since then stored at the bottom of a salt mine. Whilst it was mostly complete it's everything needed work. I took it apart to try to restore, moved house, stacked up the bits and never touched it. I was playing with the idea of doing a little greenlaning and making an off-road bike from something like a CG 125, plus my mate then decided we should try racing at the malle mille event next year, so my idea to do that became a little more than just the idle musing it had been. Looking at what was about at the very cheap end of the market were similarly f
ked bikes, so I thought, what the hell, let's drag it out and see if I can make some sort of functioning motorcycle out of it with very little budget. It will be "not concourse", but might be a fun wee thing to blast round the countryside on.The pistons were seized like crazy so that was the first job.
Photos will jump around a bit from the "live" project, and there are also some as-bought and during the initial stripdown 2-3 years ago.
So, starting point, the bike as of earlier this week, my "going in" point to the project:
Got the crankcases split and freed off the pistons. Though I bent a fin on the barrels like a tt.
The plan was to split the cases, hang the crankshaft down off the rods like a swing then wallop the fk out of the pistons, which have been sat in oil/diesel for a year or two. Just about got it moving, then LO! there's a hard stop at the bottom of the crankcases where the pistons physically won't fit through and just sit on the skirts. So it was turn the engine upside down and whack the barrels slowly off. And miss and bend a fin.
Possibly didn't need to split the cases then, but it was a bit of fun. I am just winging it. I've never been further into an engine that a top end rebuild.
I also dragged the frame out and started to primer it (not very professionally I'll admit). I've decided I want to make the frame British Racing Green. The reason for this is that I have a can of it kicking round from another project.
So, starting point, the bike as of earlier this week, my "going in" point to the project:
Got the crankcases split and freed off the pistons. Though I bent a fin on the barrels like a t
t.The plan was to split the cases, hang the crankshaft down off the rods like a swing then wallop the f
k out of the pistons, which have been sat in oil/diesel for a year or two. Just about got it moving, then LO! there's a hard stop at the bottom of the crankcases where the pistons physically won't fit through and just sit on the skirts. So it was turn the engine upside down and whack the barrels slowly off. And miss and bend a fin.Possibly didn't need to split the cases then, but it was a bit of fun. I am just winging it. I've never been further into an engine that a top end rebuild.
I also dragged the frame out and started to primer it (not very professionally I'll admit). I've decided I want to make the frame British Racing Green. The reason for this is that I have a can of it kicking round from another project.
Bit of a pause while Christmas happened. New crankcases have arrived. The original bottom case was a bit broken where the gearchange shaft was supported, when the bike was originally crashed, so I ordered a full set. That was a good thing seeing as now the top case is completely FUBARed. I also need new barrels and pistons now seeing as they fell out of my car with the top crankcase, never to be seen again. So the only original bit of the engine will be the gearbox shafts, crankshaft and head! Not originally the plan.
Here's a couple of pictures of the bike as I bought it.
Forward planning has never been my strong suit. Didn't think of the fact that I had no bike ramp to get it out the van once at home.
Here's a couple of pictures of the bike as I bought it.
Forward planning has never been my strong suit. Didn't think of the fact that I had no bike ramp to get it out the van once at home.
Edited by crofty1984 on Thursday 29th December 22:06
Edited by crofty1984 on Thursday 29th December 22:07
FORKS!
Bad news - The fork stanchions are beyond pitted - I've never seen anything that bad.
Good news - brand new fork stanchions are available.
Bad news - they're 300 quid EACH
Good news - Gpz 305 forks are also 31mm
They'll need some fettling I'd imagine, at least a front wheel spindle and some solution to mount the brake caliper. But they'll do me for 40 quid.
Bad news - The fork stanchions are beyond pitted - I've never seen anything that bad.
Good news - brand new fork stanchions are available.
Bad news - they're 300 quid EACH
Good news - Gpz 305 forks are also 31mm
They'll need some fettling I'd imagine, at least a front wheel spindle and some solution to mount the brake caliper. But they'll do me for 40 quid.
Another update!
I've been busy.
So, I lost half the engine in an incident. I bought some new barrels and crankcases and have been attempting to make a good one out of two. Managed to salvage the gear shift mechanism and dogs from the old engine. The bottom end's all together now!
Engine was on pause until I managed to get to a mate's workshop to hone the barrels out and check the pistons were OK. They are
Started piecing the rest of it back together. Good bit about little bikes - they're light enough to use a pair of packing crates and a bit of carpet as a work stand (and lift it on and off).
I've been busy.
So, I lost half the engine in an incident. I bought some new barrels and crankcases and have been attempting to make a good one out of two. Managed to salvage the gear shift mechanism and dogs from the old engine. The bottom end's all together now!
Engine was on pause until I managed to get to a mate's workshop to hone the barrels out and check the pistons were OK. They are
Started piecing the rest of it back together. Good bit about little bikes - they're light enough to use a pair of packing crates and a bit of carpet as a work stand (and lift it on and off).
Used to use a CB200 as a quarry bike complete with the most off road orientated tyres we could find - the "Avon Speedmaster MKII" - this combined with the removal of both mudguards as well as the number plate meant we could cope with the muddy stuff at the bottom was well as the harder surfaces on the way out.
To this day I was amazed at the abuse it took - proper strong little bikes
Your still looks better than the one we abused
To this day I was amazed at the abuse it took - proper strong little bikes
Your still looks better than the one we abused
The bike's been on pause for about 6 months while my shed was full of our new kitchen, but I've been busy!
So, remember when I said Kawasaki GPZ305 forks are the same diameter? LIES! DAMNED LIES! So decided to go all in and find a way to attach Kawasaki yokes to the Honda frame. Further compleximacated by the fact that they're designed for clip ons, not upright bars. So quite a lot more work than intended.
So, remember when I said Kawasaki GPZ305 forks are the same diameter? LIES! DAMNED LIES! So decided to go all in and find a way to attach Kawasaki yokes to the Honda frame. Further compleximacated by the fact that they're designed for clip ons, not upright bars. So quite a lot more work than intended.
Edited by crofty1984 on Saturday 17th February 23:08
I'm so glad you have resurrected the thread! Looking forward to more, now!
This might inspire you.
https://youtu.be/9DOghE25A3w?si=pvRYKKHpef69q-Ak
This might inspire you.
https://youtu.be/9DOghE25A3w?si=pvRYKKHpef69q-Ak
Rebuilding the head.
Bought these valve clamps. I did have a set of the lever type ones but they were st (admittedly cheap, but then so were these). These are much more useable and can be repurposed for clamping that bit of skirting board on the pantry back.
Getting some of the old valves and the camshaft out was a bit of a mission. Enthusiastic persuasion was needed. If I remember correctly I had to take it out the wrong way because the camshaft, points cam and plate had spent the last 40 years becoming one. All the super helpful videos of "...and then just lift off the plate" suggested that this task would be much more easier and much more peasier than it in fact was.
Bought these valve clamps. I did have a set of the lever type ones but they were s
t (admittedly cheap, but then so were these). These are much more useable and can be repurposed for clamping that bit of skirting board on the pantry back.Getting some of the old valves and the camshaft out was a bit of a mission. Enthusiastic persuasion was needed. If I remember correctly I had to take it out the wrong way because the camshaft, points cam and plate had spent the last 40 years becoming one. All the super helpful videos of "...and then just lift off the plate" suggested that this task would be much more easier and much more peasier than it in fact was.
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