XR200R Pit Bike Project

Discussion in 'Some Assembly Required' started by JagLite, Jan 2, 2017.

  1. JagLite

    JagLite Long timer Supporter

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    I considered that but I thought if the plate could move it would not keep the anchor block in the swingarm channel.
    I'm sure there is an easy solution for that but I didn't think of one.
    And by floating on the axle, you must mean over the axle spacers?
    If between the spacers, it doesn't move.
  2. Salsa

    Salsa Long timer

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    Yes that is what I mean.

    Don
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  3. JagLite

    JagLite Long timer Supporter

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    More fun shop time yesterday. :jkam
    I filled the rear brake system.
    That took a lot longer than expected.
    But, after an hour and using my hand vacuum pump along with constant refilling the reservoir I finally felt it doing something and the bubbles in the line ended.
    Then I adjusted both the shifter and brake pedal height with my boots on, all good so far.

    I also mounted the front fender that has been taped in place all this time.
    Which required surgery on the plastic so the fender would fit up to the bottom triple clamp:

    [​IMG]

    And an aluminum plate to match the holes in the fender to the holes in the bottom clamp.
    The plate bolts to the fender, then the fender and plate bolt to the bottom clamp, each has 4 bolts.

    I said surgery but really it is more of a butcher job on the plastic:

    [​IMG]


    [​IMG]

    [​IMG]

    I did smooth the corners and edges of the plate before final installation and locktite:

    [​IMG]

    And finally, mounted up:

    [​IMG]

    I see I need to get some gloss white Krylon Fusion paint for the fork guards so they will better match the frame. :hmmmmm

    I started on the next bit I need to install, can you tell from the picture below what it is going to be?

    [​IMG]

    That is 1/8" UHMW plastic

    Did I mention I ordered a new sprocket that is the correct chain size (520)?
    From Sprocket Specialties who also made the sprocket for my Rickman. :nod :thumb
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  4. JagLite

    JagLite Long timer Supporter

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    Oiled and installed the air filter:

    [​IMG]

    I cleaned off the build table finally too:

    [​IMG]

    [​IMG]

    [​IMG]

    Just realized I need to make a skid plate for the bike too. :hmmmmm

    Did you notice how much the front fender looks like the beak on the BMW GS's?
    Maybe I will get another one to install on my TW-Strom project :hide Stick a couple BMW stickers on it and really mess people up. :evil

    As a reminder, this is what the Honda looked like when I bought it:

    [​IMG]

    [​IMG]
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  5. JagLite

    JagLite Long timer Supporter

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    It was a nice surprise to have the new sprocket and bolts arrive today since I didn't expect them so soon.

    Bolts and nuts from Bolt Depot ($10), sprocket from Sprocket Specialties ($80):

    [​IMG]

    What a difference between the 47 tooth 428 sprocket and the 47 tooth 520 chain sprocket:

    [​IMG]

    [​IMG]
    And the weight difference is huge too.
    The smaller steel sprocket feels 4 times as heavy as the aluminum.
    I don't have a way to weigh things that light but it is very noticeable.

    I remembered to take a picture of the sprocket side axle spacer:

    [​IMG]

    [​IMG]
    [​IMG]

    And how the axle arrangement is:

    [​IMG]


    I bolted the new sprocket on with the new bolts and installed the wheel:

    [​IMG]

    Now to see if the chain is long enough with the larger OD sprocket:

    [​IMG]

    Good! I just need to remove two links and it will be right.

    Easy:

    [​IMG]

    And it fits just right.

    [​IMG]

    I also bought new bolts for the rear brake caliper to replace the old, too long bolts I have been using.
    I needed 15mm long but the shortest the local True Value hardware store had is 20mm so I had to shorten the two bolts.
    I put on one or two nuts on a bolt before cutting it to give me a guide for the hacksaw and to clean the thread as I remove the nut.

    One bolt shortened and the other ready to cut:

    [​IMG]

    I file the end of the bolt before removing the nut(s):

    [​IMG]

    [​IMG]

    I will work more on the custom chain slider I'm making from UHMW by trimming it to size/shape, drilling the mounting screws, and install it:

    [​IMG]

    It is cut oversize so that I can shape it to match the swing arm better.

    Coming soon is the lower chain guide and skid plate... :ricky
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  6. dirt hokie

    dirt hokie Long timer

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    that is one bad ass XR 200
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  7. JagLite

    JagLite Long timer Supporter

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    I was able to play in the shop some more yesterday. :rayof
    First thing was to add another important tool to my shop.
    A massage chair to work out the kinks, aches, and pains. :jkam
    While giving me another thinking chair to work out details, and watch bike stuff on the flat screen.
    Actually, it was in the house but there is no longer room for it so rather than give it up, I moved it out.

    [​IMG]

    The final shape of the swingarm guard:

    [​IMG]

    Installed:

    [​IMG]

    [​IMG]

    Did you notice my super trick master link keeper? :D

    And super trick tool keeper:

    [​IMG]

    And what lessons have I learned this week?

    Buy the Honda swingarm chain guard. :baldy
    Oh, well, that's how things go sometime.
    It took ridiculously long to fit and shape my slider.
    I will see how long it lasts and order the Honda part when I need a new one.

    Another lesson is that there must be some type of chain roller/guide under the chain at the frame.
    The chain will rub on the frame when the suspension is fully extended and the chain is whipping up and down.
    I will search the parts fiches to find what Honda used and then make my own if I can't locate the Honda part.

    I do need to make a chain guide/guard near the rear sprocket too.

    I decided to rebuild the muffler (again) since I don't care for how the bike sounds with it now.

    [​IMG]

    I have two more cores to test and see which sounds better.
    The muffler as is now is a chamber design and it is loud and very sharp, (metallic?) and I want a deeper, muffled sound like a glass pack.
    Which is what the new cores are, straight through but smaller diameter and the can has plenty of room for the glass packing.

    End of day picture:

    [​IMG]
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  8. Foxed101

    Foxed101 Monkeywrench

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    It’s really coming along!
    Nice job Jag:nod

    Wouldn’t be able to afford one myself...

    Keep topping up the adult mini with vodka would put too much of a drain on finances:D
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  9. NorthernTraveler

    NorthernTraveler Long time Adventurer

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    The bolt hole right above the left footpeg is for the Honda lower chain slider.
    Honda just uses a slider block.
    I've changed it over to a small chain roller on some of mine.
    Either will work.
    The stock Honda chain slider is pricy, and only seems to fit the 200. I did a cutting board one...
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  10. JagLite

    JagLite Long timer Supporter

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    Thanks NT, :thumb
    I ordered the swingarm parts last night from Partzilla. :doh
    I got the front slider block and mount and the rubber swingarm protector.
    I couldn't tell from the parts fiche how that front piece bolts onto the swingarm so it makes sense now that it bolts to the frame.
    I remember there is a hole in the frame behind/above the footpeg but there was nothing there before and I couldn't find any picture in the manual for what it might be for. Then the parts fiche shows it with the swingarm... :scratch

    I'm sure my UHMW slider will work for a while but I had to have something at the frame to keep the chain from cutting it.
    As long as I was ordering that I decided to go ahead and pay the extra $32 for the genuine Honda swingarm guard.
    Since my swingarm is from a '90 to '95 XR250L I needed to get the guard for it.
    I like the idea of a roller much better than the slider at the frame but I will use the stock part at first and when it wears I will figure out how to install a roller instead.

    I didn't order the rear chain guide since my sprocket is so large, but I did order the plastic wear part and I will use it when I make my own side plates to hold it.

    That 1/4" aluminum plate scrap pieces I bought have sure been handy for several projects.
  11. villageidiot

    villageidiot Long timer Supporter

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    Moose makes a roller bearing chain roller commonly swapped into dr650’s
  12. JagLite

    JagLite Long timer Supporter

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    Thanks for the suggestion!
    I have roller bearing rollers on both my DR650's too.
    I bought mine from ProCycle where I get a lot of parts for my various bikes.
    Finding a roller with bearings should be easy, it is figuring out how to mount it strongly that will be the question.
    I ordered the bracket for the stock slider and I will see how the bracket bolts on.
    That will give me ideas of how to improve the slide with a roller.
    I really don't want to weld on the frame now that it is powder coated but if necessary I will weld on a tab or two to bolt the parts to.
    Time will tell... me something. :confused :dunno
    But, will I listen? :fpalm
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  13. villageidiot

    villageidiot Long timer Supporter

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    If you got a bracket with 2 bolt holes, just a stud and nut should be sufficient for the chain roller. Make the new bracket thick enough not to deflect and you should be fine.
  14. JagLite

    JagLite Long timer Supporter

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    It only has one bolt holding it to the frame as far as I can tell.
    Here is the stock slider mount and block, #5 is the mount, #11 is the slider block.
    #12 is the sleeve for the bolt (#27)
    When the parts arrive and I can figure out how it bolts on I will have a better idea

    upload_2018-11-28_12-34-27.png

    Honda used the same parts on a lot of the XR 200 & 250's so it must work.

    The BIG picture:

    upload_2018-11-28_12-39-8.png

    Part #15 is not available but appears to be an upper slider over the chain
    I ordered #13 & #10 too.
    I will make my own #9 part to bolt #10 to so it fits my large sprocket.
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  15. JagLite

    JagLite Long timer Supporter

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    For anyone interested in building, or just riding a Honda XR200R or similar bike (XL200, etc.) I have found more information over on Thumper Talk forum than here. Probably because not many are crazy enough to consider riding a 200cc bike on an adv ride. Although I think it would be much, much more enjoyable on most offroad rides than any BMW. The big bikes are only better when on paved roads.

    Here is the list of threads over on TT that I follow:

    upload_2018-11-30_6-58-43.png

    There is not much activity but the few who are active keep an eye on their threads for when a question is posted.
    There are more threads on the XR200's there, these are just the ones that I have used to build my bike.

    HERE is a link to the main directory for the small bore Honda's.

    I will mention that some of the posters on TT are not as helpful as most are on advrider.
    If you ask a question, make sure that you state how you have searched for the answer before asking or you will probably just get a reply to "Search", or "That's already been answered, just read the thread".

    I have never had anyone on advrider give that type of response when I have asked a question. :thumb
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  16. JagLite

    JagLite Long timer Supporter

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    There's a whole lotta shakin' going on here in Anchorage today...

    Earthquakes that is, two large ones and many strong aftershocks.

    I ran home and checked on the folks, the wife, the dogs, the house, and the bikes.
    All good. Whew! I was worried about my bikes! :D

    I knew everything else would be fine, we are used to shakers.
    This one was especially strong because it centered less than 10 miles away and the two initial strong quakes lasted a good while.
    I haven't seen duration reports yet but I will guess 20 seconds for the first two and a few seconds for the many aftershocks.

    There are lots of wild reports going around by phone and online of bridges collapsing and building breaking up.
    Most of our office (engineers) are out doing rush building inspections but are not finding any damage other than the usual.

    One offramp did have a serious problem for one driver:

    [​IMG]

    With all the shaking and rolling around during the quakes I can guess the driver was afraid the ground might just open up and swallow his/her car. The driver will probably be on TV before long telling the story.


    I did see one picture of serious damage. :(



    This picture is not for the faint of heart or stomach. :puke2




    Viewer discretion advised! :dirtdog




    upload_2018-11-30_13-3-49.jpeg

    Oh, no!!!!!!!! :yikes
  17. mach1mustang351

    mach1mustang351 Long timer Supporter

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    glad everyone is good in your family. We did well too. I don't know, this one was different for me. I have been on edge since 830. Lived my whole life in CA, 8 years in AK, I thought I was an earthquake pro... Apparently not
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  18. JagLite

    JagLite Long timer Supporter

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    This one had a lot of sharp, or sudden shakes that really moved the ground and buildings.
    Usually they are not so sudden, more a rolling than a shake it seems to me.

    Here is another great picture of that lone car on the offramp:

    upload_2018-11-30_14-59-14.png

    For those of you outside, it was dark since it hit this morning before sunrise at 8:30 am.
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  19. mach1mustang351

    mach1mustang351 Long timer Supporter

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    I agree. Definitely a shake, versus the usual rolling feel. It also came on quick, there wasn't a real build to it. The duration was probably the scariest to me, of course it felt like it was going on for 20 minutes, but most reports are saying 90 seconds. Usually the big shakers are short 30 seconds maybe.

    It was definitely crazy
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  20. JagLite

    JagLite Long timer Supporter

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    It gave us something to talk about around the coffee machine, after we stood it back up. :lol3
    I'm at ground level so I had the minimal effect, the upstairs offices got a lot more damage with ceiling tiles falling, pictures jumping off their hangers, computer monitors crashing off desks, and things like that.

    I'm sure we will hear a lot more from people in the taller buildings!
    10th floor? NO thanks! :pep

    Imagine being inside an elevator when it hit?
    You would think you are about to die. :uhoh :yikes :grim

    The engineers are now examining the bridges.
    The airport has reopened it is reported.
    (It was closed just to inspect the buildings)

    We are still getting aftershocks that we can feel at 3:45 pm :vardy

    There will be hundreds of minor shocks that we won't feel.

    This is nothing in comparison with the fires in California, the hurricanes, the floods, the tornado's and other disasters.

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