Honda CB200 / CL200 Scrambler Shop Manual – 1974 (P/N 6135402)

Honda Motor Co., Ltd.'s CB200-CL200 Shop Manual (P/N 6135402) uses the CB200 as its foundation and adds explanations and photographs for CL200 Scrambler differences. The cover carries a 1974 copyright, while Honda's preface bases the service information, illustrations, and specifications on the 1973 model. A CB200T addendum is included.

PDF Bookmarks, Wiring Detail, and Included Pages

Search and diagram viewing: PDF text search is not available. Embedded bookmarks link to the main sections and many component topics. The wiring pages are sideways, and small labels require rotation and zooming.

The ZIP contains one printable, English-language PDF with 98 pages, including the cover, preface, two blank pages, the four-page CB200T addendum, and the final brake-indicator sheet.

Engine Overhaul, Chassis Service, and Electrical Testing

These selected coverage highlights outline the main workshop areas rather than reproduce the full contents. Other topics include air-cleaner service and headlight-beam adjustment.

• Top end and engine removal: Engine removal and installation; cylinder-head, camshaft, cylinder, and piston disassembly; valve and guide inspection; cylinder and piston measurement; valve timing; cam-chain tensioner setup.

• Lubrication, clutch, and kick starter: Plunger-type oil pump, centrifugal and screen filters, wet multi-plate clutch disassembly and wear inspection, kick-starter mechanism, starter chain, and post-assembly oil-pump check.

• Transmission and shifting: On-frame gearshift service, constant-mesh gearbox disassembly on a work stand, crankcase separation, mainshaft and countershaft removal, gear backlash measurement, and shift-drum and fork inspection.

• Carburetor service: Disassembly, jet and float-valve inspection, float-height measurement, throttle-valve installation, idle adjustment, and separate model-specific carburetor setting tables.

• Brakes and wheels: Cable-operated, self-adjusting front disc brake; drum-brake front wheel; rear drum brake; axle, bearing, rim, spoke, and driven-sprocket service.

• Steering, suspension, and frame: Handlebar wiring and cable routing, steering-stem bearing adjustment, front-fork disassembly and seal replacement, rear shock and swingarm service, and frame-body stripping and inspection.

• Electrical diagnosis: Breaker-point ignition timing with a test lamp or timing light, ignition-coil and condenser tests, alternator output, rectifier and regulator checks, starter-motor and magnetic-switch service, and switch continuity tests.

Honda prepared this manual for the mechanic responsible for upkeep; owners undertaking the starred maintenance items need the proper tools and mechanical proficiency specified in the maintenance schedule.

Repair Procedures and Reassembly Guidance

Step-by-step disassembly and inspection procedures cover major repair work, including top-end overhaul and internal gearbox service. Crankshaft coverage includes removal, runout measurement, connecting-rod side-clearance inspection, and bearing-alignment points.

Full reassembly sequences are generally not repeated. Honda directs the mechanic to reverse the disassembly procedure while following the specific “Reassembly points” provided throughout the manual.

The carburetor setting table distinguishes CB200 setting number 008A from CL200 setting number 027B, with different jetting and air-screw settings. This model-specific reference helps distinguish the applicable fuel-system setup before adjustments or parts are selected.

CB200T Changes and the Brake-Indicator Sheet

The CB200T addendum documents revised fuel-cock markings, discontinuation of the right-handlebar headlight switch, lighting control through the main switch, and the new left-hand dimmer switch.

Its shock-absorbing side-stand pad coverage includes inspection, return-force testing, pad wear and replacement, and an added maintenance item. A dedicated CB200T wiring diagram accompanies these changes.

The final sheet explains the FMVSS 122 brake-shoe wear indicator and applies specifically to CB200 frame serial CB200–1010116 and subsequent. That serial break belongs to the brake-indicator sheet.

Wiring Diagrams, Troubleshooting, and Workshop Tools

Five full-machine wiring diagrams cover U.S.A., U.K., European, French, and CB200T configurations. Separate circuit drawings show the ignition system, charging system, charging-test circuit, and starting system.

Workshop illustrations include the engine cutaway; cylinder-head, camshaft, cylinder, and piston exploded view; clutch assembly; transmission mainshaft and countershaft; cable-operated front disc caliper; and front-fork assembly.

The maintenance schedule, component torque tables, assembly standards, wear limits, and model specifications support inspection and repair planning. Troubleshooting tables connect no-start and no-spark symptoms, clutch and shifting faults, steering and brake complaints, and insufficient charging with probable causes and remedies.

The special-tool table identifies Honda set 07900-3540000 and individual tools by number. Examples include rotor puller 07933-2160000, piston-ring compressor 07954-3230000, and valve-spring compressor 07957-3290000. Fork-seal driver 07947-3550000 and shock-absorber compressor 07959-3290000 cover suspension work.

Shift-Fork and Electrical Repair Cautions

Installing the center shift-fork guide-pin clip from the wrong side can make it interfere with the gear and damage the shifting components. Correct battery polarity is equally important: Honda warns that reversed connections can damage the rectifier diodes or burn the wiring harness.

Support the motorcycle securely during wheel, brake, and suspension work, and keep grease or oil away from friction surfaces. Fuel and solvent work requires ventilation, while battery charging must be kept away from sparks and flame because it produces hydrogen gas.

Selected Fork-Fill and Clutch-Wear Specifications

The front-fork service data distinguishes a routine drain-and-refill quantity of 115–118 cc of ATF per fork from the 128–132 cc required after disassembly. These separate fill conditions accompany the fork oil-change and overhaul instructions.

For clutch inspection, Honda lists a standard friction-disc thickness of 2.92–3.08 mm and a service limit of 2.6 mm. The clutch section places these measurements alongside plate-distortion and spring inspections.