How to Get your CB200 Running

What you need to do to get your Honda CB200 Running

1. Clean the Carbs - fully disassemble and clean everything with carburetor cleaner. Take out all the brass parts (jets, float valve, etc.) clean or replace everything.
   
   • I used a welders "Tip Cleaner" set. Find a welding supply store in your area and ask for a torch tip drill set. You'll get about fifteen drill bits housed in a pin vise from .0625 (1/16th) down to super small for about seven or eight bucks and they are very high quality. This will allow you to clean every passage in the carb.
     
   • Soak the stripped down carbs overnight in a carb cleaning solution. Berryman / 1 gal. B-9 carburetor and parts cleaner with basket is $20 at AutoZone. Warning it will eat all rubber.
     
   • Reassemble the carbs with a pair of Quality Keyster carb repair/rebuild kit made in Japan $22 each from Out West Motorcycles.
     


2. Drain Gas tank - clean and refill
   • Remove your tank... close the petcock, pull the fuel lines, open the seat, pull back the harness at the rear of the tank, lift and slide the tank back. (No tools.)
   • Empty the contents into a container. This will be varnished gas and rust.
   • Remove the petcock from the bottom of the tank. the 75 uses a Phillips-head screw.
   • Fill the tank with water and empty multiple times. This will float out the big loose stuff.
   • Reinstall the petcock.
   • Pour a pint of liquid degreaser full strength and a couple 8" lengths of medium size linked chain into the tank and slosh vigorously with all the openings capped off. (There are people who will put screws/nuts/bolts in the tank, other people report losing/not recovering all the bolts. Use a couple of chains so can make sure you get them out when you are done.)
   • Add a 1/2 gallon of the hot water to the degreaser still in the tank and slosh it around again for a few minutes.
     
   • Empty the tank, remove the chains.
   • If you still have rust, fill the tank with Vinegar, let it sit overnight and then empty. Do this several times until the vinegar coming out is clear.
   • Finally pour about a tablespoon of hand dishwashing liquid and about a gallon of very hot water into the tank and slosh thoroughly. Dry the tank.
   • Remove the petcock, disassemble and clean thoroughly.
     
   • Kreem the tank
   • Reinstall petcock, fill with new fuel.
   • Replace fuel lines with inline fuel filters.
     
3. Change the oil. Your CB200 uses 3.6 pints (1.75 Quarts) of 10W-40. There's a large nut at the bottom of the motor. Remove that with a 19mm socket to drain the oil. There is no oil "filter" as it is equipped with a centrifugal oil filter in the motor.
   
4. New battery - The bike came stock with the YuasaMBW3-12C. Get the Yuasa YB9-B from your local dealer, its about $30. They will fill it with acid and do the first charge on it for you. Don't think you need a new battery? Here's some good advice. http://en.allexperts.com/q/Motorcycle-Repair-837/1975-Honda-CB200-Electrical-1.htm
   
5. New plugs - While your at the dealer pick up a new set of spark plugs. NGK D-8ES-L. If your motor has been sitting a long time while you have the plugs out you can spray a little penetrating oil inside chamber & rotate engine without the plugs in. Let this sit for 24 hours before firing the bike up.
6. Check the tires and pressure. Old cracked tires on motorcycles spell potential disaster, one of the first things you'll want to do is to replace the tires. Use 80/100H-18 in the front and 90/90H-18 in the rear. At the very least check the tire pressure in the old tires 26 PSI in the front 28 PSI in the rear.
   
7. Lube the chain. If you need to clean the chain stay away from WD-40, remove it and soak it in Kerosene. Lube the chain with a good quality chain lube and you'll be good to go!