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

This 98-page PDF contains Honda Motor Co., Ltd.'s CB200-CL200 Shop Manual. The cover carries a 1974 copyright, while Honda's preface states that the service information, illustrations, and specifications are based on the 1973 model. The manual uses the CB200 as its foundation and adds explanations and photographs for CL200 differences. It covers the 198cc air-cooled four-stroke OHC parallel twin, wet multi-plate clutch, five-speed constant-mesh transmission, and the related chassis and electrical systems. Honda prepared it as a service guide for the mechanic responsible for upkeep; its deeper repair work is suited to technicians or mechanically proficient owners equipped with the specified tools, consistent with the maintenance chart's own service guidance.

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

• Lubrication, clutch, and kick starter: Details the plunger-type oil pump, centrifugal and screen filters, clutch disassembly and wear inspection, kick-starter mechanism, starter chain, and post-assembly oil-pump check.

• Transmission and shifting: Separates on-frame gearshift service from work-stand disassembly, then covers crankcase separation, mainshaft and countershaft removal, gear backlash, shift-drum and fork inspection, and constant-mesh gearbox repair.

• Brake and wheel configurations: Provides distinct repair sections for the CB200 cable-operated, self-adjusting front disc brake and the drum-brake front wheel, plus rear drum-brake, axle, bearing, rim, spoke, and drive-sprocket service.

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

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

• Service data and fault isolation: Supplies the maintenance schedule, component torque tables, assembly standards, wear limits, model specifications, numbered special tools, and troubleshooting charts for engine, transmission, chassis, brake, and charging faults.

CB200T and Serial-Specific Material

The four-page CB200T addendum documents the revised fuel-cock markings, discontinuation of the right-handlebar headlight switch, lighting control through the main switch, the new left-hand dimmer switch, and the shock-absorbing side-stand pad. Side-stand inspection, return-force testing, pad wear and replacement, an added maintenance item, and a dedicated CB200T wiring diagram are included.

A separate final sheet explains the FMVSS 122 brake-shoe wear indicator and applies specifically to CB200 frame serial CB200-1010116 and later.

Factory Diagrams, Tools, and Specifications

Five full-machine wiring diagrams cover U.S.A., U.K., European, French, and CB200T configurations. Circuit-specific 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 special-tool table identifies Honda set 07900-3540000 and its individual tools by number. Examples include rotor puller 07933-2160000, piston-ring compressor 07954-3230000, valve-spring compressor 07957-3290000, fork-seal driver 07947-3550000, and shock-absorber compressor 07959-3290000. Troubleshooting tables trace no-start and no-spark conditions, clutch and shifting faults, steering and brake complaints, and insufficient charging.

Repair Details and Scope Limits

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.

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.

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.