Honda CT200 Tear Down ~ A Huge Thank You To BallBearian!

[NewRidersOldHonda]

Hello everyone. Shout out to BallBearian for the free CT200 engine and Carb. Greatly appreaciated!
This engine will likely serve as a great parts resource for me.
I started off removing the rocker assembly, head, and cylinder






Next step was to remove the clutch

With the clutch cover, side case, and spring mechanism out of the way, the clutch can now be removed using a special tool and socket aqcuired from DrATV...once the selector unit, and oil filter/filter cover are removed.

Selector arm removed, you can see here one screw has been previously damaged. That will be taken care of later. For now lets remove the filter cover

With the filter cover removed, here is the nut to remove the clutch, along with visible socket required and holding tool both visible. You must bend one of the tabs out of the way before the socket will be allowed onto the nut. This washer/tab combo prevents the nut from backing off.

With the clutch removed, the gear oiler, primary drive gear, gear selector/ drum stopper, and camshaft can now be removed and our focus will attend to the opposite side of the engine


Selector splines on both ends look great. Will be useful.

Questionable camshaft lobes...now onto the other side to remove what is left of the points plate.


With the points plate removed and the stator cover off, the stator and magnet are now accessible. Time to remove those, as well as the final chain drive gear.

Now time to seperate the case halves, and remove the remaining internal assemblies. I will do this in a follow uo reply, as I have reached the maximum allowance for pictures in one post.

 

[NewRidersOldHonda]

Okay, case halves have been seperated. Note the typical broken kick starter stopper in the casing cast. Three engines torn down so far and they have all had this same issue. Lol.
Now onto the crank removal, it simply slides out when pulled upon.


Very slight surface rust. I think this will be useful as well.

Kick starter splines look great as well.

Here is the transmission, gears and dogs all look to be in solid condition. Score! That wraps up the dissasembly...here are all of the parts bagged up and ready to be stored for future use. Quite a simple engine.

 

[NewRidersOldHonda]

All three of my CT200 pushrod engines have now been dissasembled and stored seperately, to eventually build one solid engine using the best of each part. I will start another thread in the future, of that assembly, but for now this is a great start. Again huge thanks to BallBearian for your generosity and enthusiasm towards honda project, you meet the nicest people on a Honda!

 

[stl360+450]

Very nice and very generous of @ballbearian! Much respect.

 

[ancientdad]

Man, this takes me back.... worked on these pushrod singles when I was 15, learned a lot about them while learning the limits of 6mm bolts too.

 

[Mikey G]

I've got one of the early overhead cam CT90s (that still has the leading link suspension), but I've always kind of wanted a pushrod 90 too. I've been keeping an eye out, but I've got way too many other projects to be serious about it.

It's neat seeing how one of these go together!

 

[NewRidersOldHonda]

Very nice and very generous of @ballbearian! Much respect.

He gave me the original carb as well, the old square style with the throttle cable leading into the front, not the top. I had bought a second one last summer...just to have it along with the other engine I bought. The original engine that was on the bike when my grandpa bought it had that square carb as well. Super nice of him to hook me up like that!

 

[NewRidersOldHonda]

Man, this takes me back.... worked on these pushrod singles when I was 15, learned a lot about them while learning the limits of 6mm bolts too.

Thats awesome! Those bolts are...well, yeah, tricky. The first 2 engine tear downs taught me patience. BallBearian was kind enough to reassemble this engine without much torque so it made dissassembly super easy on this one, gotta love that!

 

[NewRidersOldHonda]

I've got one of the early overhead cam CT90s (that still has the leading link suspension), but I've always kind of wanted a pushrod 90 too. I've been keeping an eye out, but I've got way too many other projects to be serious about it.

It's neat seeing how one of these go together!

They are fun to work on, patience, I am learning, is key...LOL. once I get everything together to build the first engine I will post it all and probably go into more depth

 

[ballbearian]

I discerned that Scotty would be the perfect young enthusiast to be the next steward of this lump that was quite a challenge to dismantle, due to the rust. It's very cool to see the great pics of it now and useful commentary.
The overhead valve (pushrod) CT200 3spd auto clutch motor is actually fairly different from the 4spd manual C200 motor, so I only stole a couple parts off it.
Perhaps, I should shadow his build with one of my spare C200 motor, acquired a ways back to go into the Frankenbike C200 frame that came with my Dream for an extra $75 when I bought my Dream.
Here is Frankenbike with Scotty's CT motor when it landed. Still has the screw studded knobby tires from it's ice racing days.

Yes Mikey, there is an OHC 68 CT90 K0 (with bottom link front suspension) in the pic hiding in the shed. Now it hides on the back porch, still barn fresh and needing a new rebore/piston.

Thank you, Scotty and hope you'll come back for some wrenching here and possible further adoptions. Of course, some full beans swinging single saddle time too.

 

[NewRidersOldHonda]

I discerned that Scotty would be the perfect young enthusiast to be the next steward of this lump that was quite a challenge to dismantle, due to the rust. It's very cool to see the great pics of it now and useful commentary.
The overhead valve (pushrod) CT200 3spd auto clutch motor is actually fairly different from the 4spd manual C200 motor, so I only stole a couple parts off it.
Perhaps, I should shadow his build with one of my spare C200 motor, acquired a ways back to go into the Frankenbike C200 frame that came with my Dream for an extra $75 when I bought my Dream.
Here is Frankenbike with Scotty's CT motor when it landed. Still has the screw studded knobby tires from it's ice racing days.

Yes Mikey, there is an OHC 68 CT90 K0 (with bottom link front suspension) in the pic hiding in the shed. Now it hides on the back porch, still barn fresh and needing a new rebore/piston.

Thank you, Scotty and hope you'll come back for some wrenching here and possible further adoptions. Of course, some full beans swinging single saddle time too.

These bikes are always confusing me! LOL...
The transmission that came out of this one looks exactly like the one that was in my original engine, which was, according to my dad, a 4 speed...
I can't see what the difference would be, and there's 4 gears still, is there some slight difference or something I am not aware of? Is my dad remembering wrong and the original engine is actually a 3 speed? All of the information that I can find points to these OHV pushrod engines being 4 speeds, and the smaller 50 CC's having 3 speeds.
So glad you got to see the teardown, the rebuild will be a lot better
Also tonight I will be making another new post with all of the photos and what I've done so far to the body of the CT200 so far, now that I am used to the format and what not...

 

[ballbearian]

I think you're right Scotty. Only the 50cc pushrods had 3spds. I just thought the 4spd auto clutch began with the OHC bikes. Another design upgrade for the new (1964-early 66) 90cc OHV bikes. Honda must've been proud and going gangbusters then.
Can't wait to see pics of the whole bike.

 

[NewRidersOldHonda]

I think you're right Scotty. Only the 50cc pushrods had 3spds. I just thought the 4spd auto clutch began with the OHC bikes. Another design upgrade for the new (1964-early 66) 90cc OHV bikes. Honda must've been proud and going gangbusters then.
Can't wait to see pics of the whole bike.

Right on! Honda has always been a step ahead. I'm always blown away by engineering in general...
I did just make a post for the CT200, I edited it and the photos, once visible without clicking, are now attachements...but they are still there lol

 

[ancientdad]

I did just make a post for the CT200, I edited it and the photos, once visible without clicking, are now attachements...but they are still there lol

But you already had a build thread and I mentioned it on your new thread.