this could get long because i'm going to try not to leave anything out! i'm working on a 1976 Honda CB200t. here's a quick recap of the last few months: around easter, after a new coil and plugs, some fiddling with the points, and an oil change, i finally got the bike to start (it had been sitting since the previous october). eventually (about a month ago), i replaced the points all together, set the point gap and made sure they were opening at the right mark (F), etc. the idle speed was really high (around 3000 RPMs). so, i decided to remove the carbs, clean them, put them back on and adjust them to factory specs. i did all that and got the idle speed down to where it should be. i also did a valve adjustment. (had some help with the valves and carbs, thank god!)
it felt like the clutch cable needed some adjustment, so i loosened the top and bottom cable adjusters. then, following the manual, i tried to set the 'clutch adjuster' screw (found behind the clutch cover). i turned it in until i felt resistance, then backed out a 1/4 turn or so and retightened the lock nut. but i heard something "come loose" inside the right crankcase cover and all of a sudden i couldn't tighten or adjust the clutch cable. so, off came the right crankcase cover. and i was left trying to figure out how the 'clutch cam plate' and the 'clutch lifter' and the 'retainer' worked (they're all found inside the crankcase cover, on the other side of the clutch adjuster screw; you can see them all in this diagram:
http://www.xtremeusa.com/fiche_section_detail.asp?section=120342&category=Motorcycles&make=Honda&year=1976&fveh=2884). i think i got them all in the right way, but i really had/have no idea how far in or out that clutch adjuster screw is supposed to be. i also wanted to take a look at the gear shift mechanism under the left crankcase cover. but, i couldn't get that cover off and i didn't want to play around too much near the stator and alternator (as it was, i pushed the stator back and forth a little and tapped with a rubber mallet around the crankcase cover trying to get it to budge. when it didn't, i figured i better leave well enough alone).
now, the bigger problem is that i can't even test what i did with the clutch adjuster screw, etc. because once i put everything back together and bolted the crankcase back together, the bike wouldn't start! it seems to be some kind of electrical problem (though i'm not ruling anything out., especially because of the tinkering i did in and around the crankcase covers as mentioned above). when the ignition is turned to "on," i get plenty of juice--the neutral light is bright and (when i turn them on) the turn signals are bright and blink normally, and the horn is nice and strong. but, as soon as i turn the kill switch to run, the neutral light dims, the turn signals come on but stay on solid, and the horn is weak. and, when i kick it (i have no functioning electric starter button) i get nothing. i thought it was the battery. so, i had the battery load tested and sure enough it failed--wasn't holding a charge. i got a new battery, filled it with acid up to the right level, charged it fully, and installed it. same result.
so, today, i went out and checked wires, connections, battery terminals, etc. everything looked clean, tight and ok. i tried swapping the main fuse with a spare one that was attached to the battery cover. it made no difference with the lights, but when i kicked the bike a few times with the spare fuse, the fuse blew. i tried the other spare fuse and it blew that one too when i tried to kick the bike (blew it so bad that the heat from the fuse melted the plastic fuse case!). now, i'm fuse-less (i dropped and broke the one that was on the bike in the first place--brilliant!) and scared that i may have (or have caused) a bigger problem: rectifier, stator, alternator, solenoid...anything electrical. i'm going to try to find a new fuse (maybe the spares were bad??) and have the "new" battery tested (maybe it's bad??). other than that, though, i'm at the end of my rope. i don't have the equipment or know-how to do electrical diagnostics.
if you can think of anything i might be overlooking or offer any general advice, warnings, suggestions, slaps to the back of the head, i would really appreciate it (both in regards to the clutch cam plate/lifter/adjuster screw and the electrical stuff).
thanks a million!!
