XR200R Pit Bike Project

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

  1. NC Rick

    NC Rick Cogent Dynamics Inc

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    It’s awesome! Congratulations. We can’t wait for the ride report :-)

    Thanks for sharing.
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  2. JagLite

    JagLite Long timer Supporter

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    Okay, I changed the front fender and I do like this one better:

    [​IMG]

    Closer of the old and new fenders:

    [​IMG]

    The new fender is a two piece design.
    I bought it because of the black and white pieces matching the bike.

    It sure is handy to have a selection of metric bike bolts:

    [​IMG]

    I used captured washer bolts:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    I may put a couple washers on the rear bolts to raise the front of the fender a bit... maybe... :hmmmmm

    [​IMG]

    Last picture....

    [​IMG]

    I searched the shop but have not found my scales to weigh the bike. :dunno

    It's there somewhere I'm sure... :scratch

    I plan to take outside pictures tomorrow, and fire it up! :ricky
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  3. dbarale

    dbarale Squiddly slow

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    That did it. Looks great! Now we need a wheelie video.
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  4. NC Rick

    NC Rick Cogent Dynamics Inc

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    That’s a cool fender but it may scare you as you will now be able to see what’s coming if it’s muddy out :-)

    Seriously, I like that look!
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  5. JagLite

    JagLite Long timer Supporter

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    Thanks!

    Well, today did not go as planned.
    First I had to run the snow blower on the driveway and pathways to shift some of the 20 inches we got last week.
    But the snow blower didn't want to start with the push button.
    Starter motor spins but it isn't cranking the engine.
    So I put it in the shop to pull the starter.

    What's the problem here?

    upload_2018-12-22_20-36-3.jpeg

    all the gear teeth are sheared off! WD40 won't fix that.
    Fortunately it starts pretty easy by hand.

    When I finished that I was finally able to fire up the bike and take it outside for more pictures...
    First I poured a gallon of gas in the tank...
    Then I discovered the gas was streaming out of the bottom of the tank even though the petcock was turned off.
    What a stinking mess it made!

    I grabbed a funnel and an empty bucket to catch the fuel:

    [​IMG]

    Can you see the stream of gas?

    [​IMG]

    It is coming out at one of the screw holes.

    I waited until the gas had drained out then I pulled the seat and tank so that I could remove the petcock.

    The o-ring had cracked.
    :becca
    I went to the Yamaha dealer but they had no o-rings they told me.
    I went down the road to the NAPA auto parts store and was told they don't stock any fuel safe o-rings but they could order one for me... Pass.
    Then I went across the street to the Harley dealer and the parts guys found one for me, no charge. :thumb

    I cut a new gasket and used Yamabond to seal the gasket then bolted it back together.
    It was 4:30 by then and dark outside so I will try again tomorrow for first startup and outside pictures.
    But the skid plate arrived! Very fast shipping even in the mail.

    I hope tomorrow goes better. :dirtdog

    It's a race!:
    [​IMG]
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  6. FR700

    FR700 Heckler ™©®℗

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    *fingers crossed*

    :lurk
  7. cedric

    cedric Been here awhile

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    My 200 needed a new 4 hole gasket for inside the petcock too. It's not available from Honda but I found that one from a TRX 250 quad was a decent fit and worked. This requires drilling out the rivets.
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  8. JagLite

    JagLite Long timer Supporter

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    Outside in the snow today: :vardy

    [​IMG]


    [​IMG]

    [​IMG]


    I need a summertime in the woods background obviously. :hmmmmm

    And, I fired it up! :wings



    No, it didn't start on the first kick.


    Or the 10th, 15th, or 30th either. :dirtdog

    So I pulled the plug and saw that I need a new plug, but I did have spark anyway. :dunno
    Then I looked at one of the carbs off my parts bikes and discovered the choke lever works the opposite way from what I thought. :fpalm
    Two kicks and it popped, two more kicks and it started.
    The new muffler sounds soooooooooo much better, and it is even quieter. :thumb

    One thing I realized during all my kicking is that this puppy is much harder to kick over than my Triumph TR6C (650cc) engine in the Rickman. :eek2
    The Honda 200 has some serious compression so I wonder if someone put a high compression piston in it in the past. :scratch
    I would not think so considering the overall neglected condition of the bike when I bought it.
    Another thing I learned is that of my many sparkplug sockets and bike tool kits I don't have one that fits the plug in this bike. :confused
    A deep 18mm socket worked fine but it was quite surprising to not have the correct tool.

    The engine has an auto decompressor but it never worked so I didn't reconnect the cable.
    The kick start gear appears to be missing at least one tooth as the kicker will slip internally and not turn the engine over.

    That's the good and bad news, the ugly is that the petcock still leaks. :baldy

    It is now leaking around the lever internally. :becca
    So I pulled the petcock off my spare tank and installed it.
    No leaks! :rayof
    Until I turn it to on or res.
    Then it also leaks internally around the lever. :devildog

    Thanks Cedric! :beer
    I will order one (or two) and attempt to rebuild the valve.
    I was going to order a new petcock but now that I see you were able to rebuild yours I will try that first.

    Naked bike pictures:

    [​IMG]

    [​IMG]

    Before pulling the petcock I set the spare tank on the bike:

    [​IMG]

    Transplant completed:

    [​IMG]

    However, the patient is still in intensive care due to complications from a defective donor.:vardy
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  9. Pezz_gs

    Pezz_gs Cant ride for crap

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    The teething problems of old bikes, old Gaskets

    Think I will come across that with my build

    So what’s next James.....
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  10. Salsa

    Salsa Long timer

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    I guess you know a CRF230F motor with an Electric Start will almost fit. Well, any way mine almost fit. Maybe it was because the XR200 I took out almost fit too. I don't know how straight it was because the frame was built in the 70's to fit a OSSA 175 modified to have a Variator drive like a ROKON.

    Maybe that will be your next years project.

    Good luck
    Don
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  11. JagLite

    JagLite Long timer Supporter

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    The next project is not a custom build, just a simple basket case rebuild...







    Of a 78 year old bike! :yikes







    It looks like this now:

    upload_2018-12-23_20-13-26.jpeg

    No restoration or even cleaning and painting, nope, just careful reassembly to retain the original patina as much as possible.

    upload_2018-12-23_20-19-20.jpeg

    Boxes and boxes of parts....

    When assembled it will look like this:

    upload_2018-12-23_20-16-51.jpeg

    It is a 1940 Matchless G3L that was shipped to Africa for the war effort and was most likely a dispatch carrier bike.
    I bet all seals and gaskets will need to be replaced...
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  12. FR700

    FR700 Heckler ™©®℗

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    Ooh... :tb
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  13. JagLite

    JagLite Long timer Supporter

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    I have been searching the parts fiche's for the various years of the TRX250 and I haven't found any listing for the internal gasket. :dunno
    Since the petcock is riveted I am guessing that they expect it to be replaced if/when it leaks.

    Did you take the petcock apart and then find a gasket that fit? :scratch
    I see that Honda still has the complete petcock available so I can get a new one if I can't fix mine.
    I will drill out the rivets and take a look inside.... :hide
  14. FR700

    FR700 Heckler ™©®℗

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  15. JagLite

    JagLite Long timer Supporter

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    I opened it up:

    [​IMG]

    Cleaned inside and used some Yamabond to help seal the rubber gasket, then I polished the inside of the fuel valve.
    We (Bobby and I) went to the True Value hardware store where everyone knows Bobby's name and give him dog treats, and picked up new rivets.
    I put the pieces back together, installed it on the tank, put the seat and tank on and fired up the little bike (2nd kick).
    No leakage!


    I got to work cleaning and rearranging the shop and after ten minutes I noticed a small pool of gas under the bike and sure enough it is leaking around the lever of the petcock again.
    Just a drop or two per minute but that just won't work.

    So I ordered a new petcock from Partzilla tonight. :thumb
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  16. Baroquenride

    Baroquenride Everyone dies, but not everyone truly lives.

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    Jaglite, can you tell me a good source for the muffler hanger you have, or really just something sturdy that will hold my muffler up on my own project bike?

    Disregard, I found some simple clamps on Ebay and Amazon.
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  17. cedric

    cedric Been here awhile

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    Sorry for the late reply, but the part number I used for the petcock seal is Honda part 16955-HA2-005. There are also kits available on Ebay that I believe is that seal and a couple of screws.
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  18. JagLite

    JagLite Long timer Supporter

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    Thanks Cedric, I appreciate it very much. :beer
    I try to spend less, but I also consider the hassle factor. :hmmmmm
    I have found that at times it is worth buying a new part instead of making my own or buying a repair part.
    The new petcock should work like new while replacing the inner rubber in the old cast petcock might work, might work for a while, or might always have a slow leak due to the old age problems of the original parts.

    Funny, I can't remember how long it has been since I bought anything on Ebay, or even looked for anything there. :snore
    Some years ago that was my go-to shopping place but not anymore.
    My wife used to sell custom vintage dresses she likes to make but stopped because of the way Ebay operates and the hassles involved.

    Since I can't ride for several months I rearranged my shop to start the Matchless build...
  19. motu

    motu Loose Pre Unit

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    Pretty common on the XR200. It needs a case split to replace the idler gear which is usually the one to lose the tooth, although there may be other damaged gears in the kickstarter system.

    I blame it on the dumb kids in the '80's (probably in their '50's now) who weren't brought up on British singles, and so never learned the whole complicated method to get a big single to start. They just slammed into that kickstart...kick kick kick kick kick. No engaging the gears, bringing it up to compression, easing it over, engaging the kicksart as high as possible...and then a really good kick. I still have my TLR200 (not a Reflex) to remember how to get an XR200 going.
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  20. JagLite

    JagLite Long timer Supporter

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    I hadn't looked at the parts fiche yet to see what the likely problem is, thanks.
    I really don't want to split the cases, I have several other projects I'm working on so I will just do the best I can with the way it is.
    I should be able to bump start it easily enough if the ground is good.

    Oh, well, if/when I do need to open the engine up I will go ahead and go through everything.
    I "need" to rebuild my Triumph TR6C engine in the Rickman because it leaks oil everywhere, and I was very careful when building it! Frustrating.
    I do have the spare XR200R engine that I know needs rebuilding because the PO rode it without an air filter, in our very silty and muddy areas.
    Maybe I will put it on the engine rebuild table and go through it and switch them out next winter.
    Hopefully this one will be fine for next summer's riding season. :ricky