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Thread: 185s build (full suspension) - 2021 Update

  1. #31
    ZacH_GrifF's Avatar
    ZacH_GrifF is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Upper shock mount is done.

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    Last edited by ZacH_GrifF; 06-13-2017 at 06:11 PM.
    1. 83 185s: (the money pit) xr200 cam, 200cc cylinder, 10.25:1 piston, 83 250r front end, 450r hubs, full suspension
    2. 85 Big Red 250es: in pieces
    3. 85 200m

    4. 00 Polaris Magnum 325 2x4: stays broke
    5. 02 Yamaha Wolverine 350 4x4: trail bike

  2. #32
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    Your getting the upper hand on your project.! when is your test ride???????????? Soon ?? Ol Deuce
    DO the Best With What you got !



    My Feed back :cool

  3. #33
    ZacH_GrifF's Avatar
    ZacH_GrifF is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Pretty soon. I've gotta lead on some OG 9" r rims for the back and I have to get some tires. Most likely gonna go with the Duro hf245's, and a front max for the front. Gotta make a chain tensioner and brace up the seat subframe and it should be ready to test drive. I'm sure there's a couple things I can't think of that need to be done. I'm wanting to get it mechanically finished before I head back to school in the fall. But I just started a new internship, pay is good but i gotta wait a whole month before I get paid so pretty much trying to do stuff that doesn't cost alotta money until then.
    1. 83 185s: (the money pit) xr200 cam, 200cc cylinder, 10.25:1 piston, 83 250r front end, 450r hubs, full suspension
    2. 85 Big Red 250es: in pieces
    3. 85 200m

    4. 00 Polaris Magnum 325 2x4: stays broke
    5. 02 Yamaha Wolverine 350 4x4: trail bike

  4. #34
    ZacH_GrifF's Avatar
    ZacH_GrifF is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Pearl, MS
    --
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    So its been a WHILE, lol. College took priority and I've have since graduated. I decided to get the project back going from sitting dormant. I revisited it to see if there were things I could revisit or make better since I've learned a ton more about things having gone through and finished engineering school. I realized I was having chain alignment issues so that was the first thing I wanted to tackle before moving forward with it. I decided to strip the 185s axle down to just the sprocket hub, removed the studs too. I had a sprocket laying around and decided to use it for mock up even though it was grossly oversized at 47 teeth (I ordered a 36 tooth). My idea was to create an adapter plate the mounted to the outer surface of the sprocket hub on the axle then for mock up purposes stack washers on the inboard side of the adapter so I could perfect the sprocket alignment. It worked. I was able to determine the correct amount of space I needed between the sprocket and adapter plate. Here is the plate I made for mockup purposes. Its crude but it helped me find out what I needed.
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    I will be meeting with a guy locally the end of this week to create the final adapter plate for me using a plasma table and CAD so everything is concentric and looks nice. I grabbed a generic cheap swingarm chain guide/slider for the warrior swingarm and started cutting it up to move it over to align with the chain. Just a forewarning, a 4-1/2 inch cut off wheel on a grinder spins too fast to cut on a chain slider. It sent hot melted plastic all over my hand. Wasn't fun but I got it cut up enough to fit my situation.

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    I had a piece of metal laying around I thought would be perfect for making into a chain tensioner and set about making one.

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    The stud on the bracket wasn't long enough for the chain roller I had so I cut the end off the bracket and welded a new longer bolt in the bracket and added a gusset as well because it was still too flexible.

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    I don't have a picture at the moment but I wasn't happy with mounting the tensioner to the frame with a bolt and nut because it allowed for to much play in the setup so I welded a stud to the frame so I could have a firm mount and would be able to use a nylock nut to set the play of the tensioner similar to a trailer wheel bearing. I made some brackets to weld to the tensioner and the frame allowing for the spring to have a place to attach. I think it came out great. It works good and has decent tension. I'll see how well it works once I get to test drive.

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    Here's a view of the chain mocked up with the tensioner and slider in place. Like I said earlier the sprocket and adapter plate in this photo are just for mock up. I have a 36 tooth that I will be using for the rear but it wasn't here when I was making the plate.

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    I decided to make a mount for the exhaust since its a 200x exhaust and none of the mounts line up with whats left of the 185s frame. I just cut one off the muffler and used a factory tab that was still on the frame and rewelded it to the muffler.

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    Finally bought some rear tires. I went with Artrax MXT in 20x11-9. They were really cheap and had decent specs so I figured I'd give em a try.

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    Happy to finally have this thing as a roller on its final tire wheel package.

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    I was unhappy with how high the rear end sat so I cut the upper shock mount tabs I made previously and raised the shock in the frame as high as I could without getting into the seat pan.

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    This is how it looks with the rear lowered. Much happier with how it sits.

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    Before and after.

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    I had to order some 5/8" diameter DOM tubing for bracing the rear seat frame. No big local box stores carry 5/8 only 1/2 and 3/4. I had a 250r rear disc brake hub come in the other night and I'm happy to say that it fits as a replacement for the 185s brake drum. So I will update yall later on about making that work for the rear. I also ordered some Pro Taper Contour handle bars and the adapter to run the 1-1/8 size. That's pretty much all I have at the moment but I'm happy to be moving forward with this project again. I will say I did try to make a go kart axle work for this setup when I got back to working on it but ultimately wasn't happy with the bearing setup I came up with and scratched the idea.
    Last edited by ZacH_GrifF; 03-03-2021 at 11:39 AM.
    1. 83 185s: (the money pit) xr200 cam, 200cc cylinder, 10.25:1 piston, 83 250r front end, 450r hubs, full suspension
    2. 85 Big Red 250es: in pieces
    3. 85 200m

    4. 00 Polaris Magnum 325 2x4: stays broke
    5. 02 Yamaha Wolverine 350 4x4: trail bike

  5. #35
    patriot1 is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Awesome thread. Thanks for bringing it back

  6. #36
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    You're right. It does look a lot better with the rear end lowered.

  7. #37
    207wheelin is offline At The Back Of The Pack Arm chair racerFirst time rider
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    Congratulations on graduating college. I have contemplated putting suspension under my daughters 200s. Thanks for including so many pics and all the details. Very helpful
    207

  8. #38
    ZacH_GrifF's Avatar
    ZacH_GrifF is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Thanks guys.

    Did some Cardboard design last night. Decided the mounts I originally made were too small and I felt they were going to rip off the frame at some point so I mocked up some extra bracing to extend the mounts before I add the braces for the seat frame.

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    I'm currently working with a Hobart Flux core welder. I struggle to make pretty welds with it on this thin frame so most visual welds will be ground smooth lol.
    1. 83 185s: (the money pit) xr200 cam, 200cc cylinder, 10.25:1 piston, 83 250r front end, 450r hubs, full suspension
    2. 85 Big Red 250es: in pieces
    3. 85 200m

    4. 00 Polaris Magnum 325 2x4: stays broke
    5. 02 Yamaha Wolverine 350 4x4: trail bike

  9. #39
    Join Date
    Nov 2019
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    Florida
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    Nice work! bike looks great!
    Congrats on collage, I'm in my last semester.
    mrc_builds on YouTube Channel

    https://www.youtube.com/channel/UCmw...confirmation=1


    My Addiction
    85 200m "Tallahassee"
    84 200x "SouthPort"
    84 200x "Van Halen"
    84 250r "lucky"
    85 250sx "Enterprise"
    85 350x "The Money Pit"
    85 350x Code Red
    86 250r "Unicorn"
    86 trx250r
    88 Lt250r Suzuki

    mrc_builds saves trikes like Jimmy Swaggart saved souls back in the day -said Patriot1

  10. #40
    ZacH_GrifF's Avatar
    ZacH_GrifF is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Got the plate back from the shop. It fits great and looks like it’s gonna work just fine.

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    1. 83 185s: (the money pit) xr200 cam, 200cc cylinder, 10.25:1 piston, 83 250r front end, 450r hubs, full suspension
    2. 85 Big Red 250es: in pieces
    3. 85 200m

    4. 00 Polaris Magnum 325 2x4: stays broke
    5. 02 Yamaha Wolverine 350 4x4: trail bike

  11. #41
    ZacH_GrifF's Avatar
    ZacH_GrifF is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Some more parts showed up.

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    Decided to tackle the brakes. All the front needed was a new master cylinder and I got a new one now so the front stops. I converted the rear from drum brakes to disc. The original drum is cracked so Ive never had working breaks on this bike haha. I cant wait to have disc front and rear haha.

    I used a front caliper from an 07-09 crf150r and the rear disc and hub from an 83-84 atc250r. I notched the 185s axle housing to allow the caliper to fit. I used one of the existing dust cover flange bolt holes for the upper caliper bolt and made a plate that bolted to the lower half of the axle housing flange and bolted the lower caliper bolt to that plate. It came out great and is quite sturdy. Just need to measure what length hose I need. I'll be using a Kawi KX85 foot operated master cylinder and modify the oem foot brake lever to work with it. Im going to try to run a hand brake cable to the foot brake lever so I can have rear brakes on the left side of the handlebars.

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    1. 83 185s: (the money pit) xr200 cam, 200cc cylinder, 10.25:1 piston, 83 250r front end, 450r hubs, full suspension
    2. 85 Big Red 250es: in pieces
    3. 85 200m

    4. 00 Polaris Magnum 325 2x4: stays broke
    5. 02 Yamaha Wolverine 350 4x4: trail bike

  12. #42
    ZacH_GrifF's Avatar
    ZacH_GrifF is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Jul 2011
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    Pearl, MS
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    Just a small update. Bike is dirty from pollen and rain but just some more progress pics. Its a fully functioning bike now just in the process of tuning the carb. Bought a Dobeck SAFR tool so Ill be able to tune it with an AFR gauge. Got the rear subframe braced. Ignore the flat bar on the grab bar that's just so I can temporarily mount a battery to use the AFR gauge. I also welded on a bracket to mount the foot master cylinder for the rear brakes. Can confirm it works and stops the machine fine. Reused the stock 185s foot pedal and relocated the cable bracket to use with the master cylinder. The washers behind the master cylinder are temporary until I can make some spacers the same length.

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    1. 83 185s: (the money pit) xr200 cam, 200cc cylinder, 10.25:1 piston, 83 250r front end, 450r hubs, full suspension
    2. 85 Big Red 250es: in pieces
    3. 85 200m

    4. 00 Polaris Magnum 325 2x4: stays broke
    5. 02 Yamaha Wolverine 350 4x4: trail bike

  13. #43
    ZacH_GrifF's Avatar
    ZacH_GrifF is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Took the bike out for its maiden test voyage today haha. After getting the main jet set right using the Dobeck AFR gauge I took it for a top speed run just cuz I was curious about the gearing. Bike does 52 MPH with an 11 tooth front sprocket and a 36 tooth rear sprocket. The bike did really great. Nothing squeaked, nothing rubbed. The rear brake will lock the tires up just fine. Ive still got some adjusting to do with the carb. Its pretty rich in the midrange so I ordered some needles from jetsrus so I can dial it in. I'm out of adjustment on the needle. Bike rides really great. I've never ridden a 2nd gen 250r before so I was amazed at how cushy the front end rides haha. The rear feels a tad stiff but its really close. Both the front and rear shocks need new seals but they feel great anyways. I rode it 14 miles on some Forest service roads that are designated ohv only. I need a front fender asap because it was wet today but overall I'm really really happy with how the bike is functioning. I never would have dreamed this idea I had as a teenager would come true and work so well. Its not 250r fast or anything but its a really fun trail bike and the handling is so much better. It never feels like its gonna flip. I can throw it into a curve at speed and it just hugs the ground. The wheelbase is 7" longer now. Overall I'm really happy with this bike and I cant wait to make it look as good as it rides.

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    1. 83 185s: (the money pit) xr200 cam, 200cc cylinder, 10.25:1 piston, 83 250r front end, 450r hubs, full suspension
    2. 85 Big Red 250es: in pieces
    3. 85 200m

    4. 00 Polaris Magnum 325 2x4: stays broke
    5. 02 Yamaha Wolverine 350 4x4: trail bike

  14. #44
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    It looks good.


    Now all you need to do is get those rubber foot pegs off, before you run over a leg.
    The story of three wheels and a man...

  15. #45
    ZacH_GrifF's Avatar
    ZacH_GrifF is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Quote Originally Posted by ATC King View Post
    It looks good.


    Now all you need to do is get those rubber foot pegs off, before you run over a leg.
    I actually have some metal folding style pegs on my 200m that I’ll prolly swap over
    1. 83 185s: (the money pit) xr200 cam, 200cc cylinder, 10.25:1 piston, 83 250r front end, 450r hubs, full suspension
    2. 85 Big Red 250es: in pieces
    3. 85 200m

    4. 00 Polaris Magnum 325 2x4: stays broke
    5. 02 Yamaha Wolverine 350 4x4: trail bike

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