Built a WR200, because I didn't know they existed

Discussion in 'Some Assembly Required' started by Luke, Aug 13, 2013.

  1. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,257
    Location:
    Beaverton, OR
    Thanks. The shop is great. Rick is making huge improvements. The lights I added are rather nice too, if I may say.




    If you want to see the bike in action, look over here:
    http://omraoffroad.com/forum/viewtopic.php?f=4&t=14360

    Four of us from the OMRA forum went out last Saturday and rode some trails. It is definitely small bike country, there were 3 200 2 strokes and one 250 4 stroke
    #41
  2. dirt hokie

    dirt hokie Been here awhile

    Joined:
    Oct 3, 2007
    Oddometer:
    750
    Location:
    Eastern shore of MD
    hydro forming, cool. now to build my valveless pulse jet
    #42
  3. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,257
    Location:
    Beaverton, OR

    :eek2


    It's probably for the best that I already sold the quad chassis.
    #43
  4. dirt hokie

    dirt hokie Been here awhile

    Joined:
    Oct 3, 2007
    Oddometer:
    750
    Location:
    Eastern shore of MD
    Lockwood Hiller , have fun and wear ear plugs
    #44
  5. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,257
    Location:
    Beaverton, OR
    I finally finished up the new pipe today.

    I added a gas line for back shielding the stainless steel. This is to stop the back side of the welds from oxidizing.
    [​IMG]

    It runs off the same flowmeter as the torch. That seems to work ok, but if I do a lot of this I'll probably get a dual flowmeter setup.


    I did most of the tack welding earlier, but I added some extra tacks to make it stable and then finished the seams. Some seams had good fit and were easy.

    [​IMG]


    Others, not so much:
    [​IMG]



    The green hose going to the tail of the expansion chamber is the back shielding gas. It fills the chamber and
    [​IMG]



    Old and new:
    [​IMG]

    [​IMG]


    [​IMG]

    [​IMG]



    The new pipe is longer than the old one, and the tapers are more gradual. This was supposed to move the peak power down to a lower rpm and make more consistent torque across the rpm range. My first impression riding it around the driveway is that it does do that.

    I'm going out for a proper trail ride tomorrow, hopefully I won't dent it up too badly.
    #45
  6. jesusgatos

    jesusgatos fishing with dynamite

    Joined:
    Nov 17, 2006
    Oddometer:
    2,443
    Location:
    on the road
    Luke, that's awesome!
    #46
  7. Lutz

    Lutz Killer Rabbit

    Joined:
    Jul 17, 2010
    Oddometer:
    1,540
    Location:
    North Shore of Lake Superior
    All kinds of cool, there! Enjoy the ride, can't wait to hear about it.
    #47
  8. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,257
    Location:
    Beaverton, OR
    I didn't dent it.

    I went on an easy trail ride on Saturday, we had a mix of bikes so nothing too tricky. (for my bike. for the Triumph Tiger there were definitely some tough spots :lol3)

    [​IMG]


    [​IMG]
    (pic by Scott_PDX)


    The ride confirmed initial impressions. It's definitely lost a lot up top and gained it on the bottom. The jetting was a bit off, which I worked on after the ride.


    [​IMG]

    All three plugs were run on the same stretch of road with different main jets. The right was the original 260 jet which was a bit rich on the old pipe. It seemed a little lean on the new one. Middle is 270, and left is 280. The top speed was 42ish up the hill on the 260 and 48ish with both the 270 and 280. I'll probably stick with the 280. I'm not particularly confident that I'm reading the plugs right, but the top speed is a pretty good clue.
    #48
  9. ttime4four

    ttime4four Been here awhile

    Joined:
    Aug 16, 2011
    Oddometer:
    296
    Location:
    Portland, OR
    [​IMG]

    And one of those tough spots modified my shifter.

    :muutt
    #49
  10. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,257
    Location:
    Beaverton, OR

    I was most impressed by the 18" log that got out of your way when you hit it.
    #50
  11. Loud Al

    Loud Al .

    Joined:
    Aug 16, 2005
    Oddometer:
    3,930
    Location:
    Forest Grove, OR
    Wow you have been busy, the bike is looking good.
    #51
  12. WERA456

    WERA456 Been here awhile

    Joined:
    May 23, 2008
    Oddometer:
    205
    Location:
    North Ga. (The site of the first major gold rush)
    I have been thinking about the same thing. Do we know if anyone else has tried this?

    #52
  13. operose

    operose Mama tried

    Joined:
    Jul 11, 2011
    Oddometer:
    816
    Location:
    "upper upstate" NY
    Nice one, Luke! I really like the hydroformed pipe... Now you've got me thinkin' and that can be dangerous :evil
    #53
  14. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,257
    Location:
    Beaverton, OR
    Thanks, I'm really impressed by what changing the pipe does for the power.



    Speaking of the pipe, it got its first dent last week:
    [​IMG]

    The bike landed an 11 o'clock wheelie over a log right on the pipe. Considering the hit it took it's not in bad shape. Good thing it still works, because I tried pounding it out from the backside with a hammer and punch and the dent didn't budge.


    The offending log:
    [​IMG]



    So, time for the worlds most expensive skidplate mod.
    Start with a new welder and add some sheet aluminum:
    [​IMG]


    Here are my first three aluminum welds in years. I like this machine.
    [​IMG]



    It'll take a lot of practice to get them looking nice, but this should get the job done.
    [​IMG]


    Finished with the front tray:
    [​IMG]


    The footpeg mounts and shock linkage hang below the frame rails and they tend to get hung up on logs. So I added a slider to the back. It's got a little too much clearance to the shock mount, giving up a little extra ground clearance, but that'll be easy to fix if need be. I would have liked to box the sides in for strength, but the front triangle would fill with mud.

    Complete.
    [​IMG]


    Testing today:


    Small; still have to work on landing the wheelie, but at least the pipe survived:
    [​IMG]


    Medium; not bad:
    [​IMG]


    large; excellent:
    [​IMG]
    #54
  15. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,257
    Location:
    Beaverton, OR
    A long update:



    I've been riding the bike. It's working pretty well. The clearance with the new pipe is sometimes necessary:
    [​IMG]

    And it's easy to pick up when things don't go so well.
    [​IMG]



    I've done a little maintenance, the front wheel bearings went out and the rear brake pads wore out.
    [​IMG]
    That pad was new less than 400 miles ago. Clearly I like to use the rear brake.



    The original hand guard clamps were interfering with the brake line, so I replaced them with mounts made by GatosBros.

    Before:
    [​IMG]

    After:
    [​IMG]

    I also replaced the Ram U-bolt bracket with a bolt-mount ball.

    Combined with their pinch clamps on the bar ends the guards are much more secure. The left ones work great. I don't know about the right ones, I haven't crashed on that side yet.

    The bar end pinch clamps:
    [​IMG]


    Full disclosure: Jesse of GatosBros is a friend and wouldn't let me pay for them when I tried. So I'll spam for him instead. http://gatosbros.com/




    I added a steering damper. I had a Motosportz damper from my Husky, it worked great but the mounting setup isn't very good. A Scotts damper would bolt right up, but I like the action of the Motosportz better. Started with a Scotts upper triple clamp from ebay. Modified the Motosportz mount to fit the Scotts bolt holes. I made a bracket to clamp the damper body more securely to the mount. Added some spacers to the mount to get the right bar height. I welded them together to make the Jenga tower more stable. Extended the damper arm to reach beyond the triple clamp and added a frame bracket for the pin. End result:
    [​IMG]





    The best is saved for last. I made a new gas tank. The XR tank was working, but it was wider than the seat and got in the way of my knees when leaning forward.

    Start with 0.09" 6061 aluminum.
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]





    [​IMG]

    [​IMG]



    [​IMG]


    [​IMG]


    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]


    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]



    [​IMG]

    [​IMG]



    I have two rides on it now and it makes things much better. It also holds slightly more fuel than the original tank. The downsides are that it's heavier than the plastic tank, will eventually get dented and must be moved to access the spark plug.
    #55
  16. TwinDuro

    TwinDuro Befuddled Adventurer

    Joined:
    Jun 10, 2007
    Oddometer:
    356
    Location:
    Pac Nor-Wet, WA
    Awesome Luke! Beautiful work on the new tank, it looks fantastic. Some tight confines for the TIG torch for sure! Out of curiosity, where did the aluminum filler neck come from?

    I can definitely appreciate the Gatosbros complete redesign of the Cycra bar-end and triple-clamp hand guard mounts... I ran into a nearly identical issue with the brake line/master on the '03 YZ250 front-end on my '89 YZWR when installing a set of Pro Bends, so it's good to know these awesome parts are out there.

    So, is there an ADV "Woods Bike Of The Year" award? :evil
    #56
  17. Lutz

    Lutz Killer Rabbit

    Joined:
    Jul 17, 2010
    Oddometer:
    1,540
    Location:
    North Shore of Lake Superior
    Love the updates.
    #57
  18. Luke

    Luke GPoET&P

    Joined:
    Aug 25, 2004
    Oddometer:
    4,257
    Location:
    Beaverton, OR
    The water cooled torch is tiny compared to my old air cooled one. It's so much easier to use. I even have a shorter back cap for it, but haven't worn any tungstens down enough to be able to use it.

    The gas cap is from clarke. It's meant for converting dry break tanks to a regular gas cap.

    http://clarkemfg.com/clarke-dry-break-conversion-cap-p-12.html

    Homebuilt aircraft suppliers also sell a variety of weld-in caps, some of which are affordable. All the motorcycle ones I found that were meant for a weld-in application were either steel, too small, or poorly described.
    #58
  19. LC Garage

    LC Garage On Any Sunday

    Joined:
    Mar 18, 2011
    Oddometer:
    787
    Location:
    Columbia County
    So, is there an ADV "Woods Bike Of The Year" award?

    Just trying to keep up with Luke and his hybrid woods bike on Saturday, I had a great view all day of how well that machine works! Luke really outdid himself on this one! :D
    #59
  20. bobfab

    bobfab Long timer

    Joined:
    May 11, 2009
    Oddometer:
    1,535
    Location:
    Westminster CO
    keeps getting better :lurk
    #60