'65 Honda Trail 90 Rebuild

45 years after it left the showroom, a 1965 Honda CT200 just might ride again.

Twin carbs, both need work to yield one good one.

While body pieces are out for refinishing, I wanted to get started on the carburetor rebuild. I bought a second complete use one online in case I need any parts, which I certainly will. Unfortunately, both have similar problems. I disassembled the original carb and found exactly what I expected: a lot of gummy gunk in the float bowl. The good news is that the floats are intact and fill valve appear to work. The bad news is that the throttle insert is stuck tight -and I mean TIGHT- in both units.
 
I had hoped for this to be a one-day project, but it'll take several at my pace. First I've got to strip all of the gunk out of the float bowl and jet insert. I've got some great chemicals that are helping with that. In fact they're soaking over night. Once I get them stripped and can see what I'm dealing with, I'll attach the problem of the stuck jets. None of the industrial lubricants have worked thus far, so the next step is some brute force. I have to be careful not to break the housing, but then again I've got a spare if I need it!
 
In the photos, the top one is the one I bought online, the bottom is from the bike itself. The purchased one has a rusted source value so I will wind up rebuilding the original rather than the new one. Though the original is dirtier, it's actually in better mechanical shape.

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New (old) exhaust and rear shocks

There is a steady stream of vintage parts arriving on our front doorstep. The FedEx truck is a regular sight at our house. Most of these are used parts that I've bought online at eBay or special-interest websites. The challenge is finding the nicest-condition parts and getting them for a decent price. There is very little new stock for 1965 bikes outside of maintenance items (gaskets, piston rings, and filters).

The two latest deliveries were for a complete exhaust system and a set of rear shock absorbers. When I took the exhaust off back in June, it had rusted through in many spots. I found a much nicer exhaust system that includes both the exhaust pipe itself plus the chrome heat shield that protects the riders' legs. The heat shields are in great shape. The pipe has some surface rust but should clean up by hand without too much trouble. Here are the old and new side-by-side:

The rear shocks were an even better find. The rust on the original shocks is quite deep and they may have been a total loss, though the plastic covers are in great shape. I found a pair of replacements that look darned close to new! I'll clean up the orange plastic covers from the old shocks and put them on the newer ones.