86 200x Build

[anon3]

Picked this one up locally, it’s mainly complete but missing the carb, seat and rear fender. Got it with a 250r, which had the 200x front end fitted.

I’d like to increase the bore to 251, add an oil cooler and megacycle cam, port the head etc.

Wondering if anyone knows if the megacycle needle bearing cam works with the 86? Or only the previous generation. I know the 86 had a bearing so possibly it’s not needed.

They don’t seem to have an email address, makes it a bit harder to contact them from overseas.

Trying to keep this one looking stock.

Anyone have a 86 seat for sale?


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[anon3]

Pretty much decided to get the 251 kit from MD for this build - anyone running this?

Got the engine torn down and ready for Vapor blasting this week. Looks mint inside, seems to be on second OS bore.

Not sure about that green engine oil though....

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[Dirtcrasher]

In 86/87 Honda used ball bearings on your cam, the heads are almost always reusable, you will be buying a cam and one bearing comes on it after they press on the sprocket.

I have a new oil pump chain if you need one, lots of used but good motor parts too.

I've amassed 3 take out and 10 used 86/87 motors :lol:

[anon3]

Thanks, farrrr out, this is only the 2nd 200x I’ve seen in NZ at all.

[Dirtcrasher]

Thanks, farrrr out, this is only the 2nd 200x I’ve seen in NZ at all.

You're lucky to have it!!

[MrConcdid]

I just got mine back together this morning, My first time splitting the case, she started on the second kick, I got lucky have rode it off and on all day.
Worst part was scraping all the old gaskets off- yuck.
Otherwise it went very smoothly, I hope your does too.
here it is today with the rest.

Mrc.

[anon3]

I just got mine back together this morning, My first time splitting the case, she started on the second kick, I got lucky have rode it off and on all day.
Worst part was scraping all the old gaskets off- yuck.
Otherwise it went very smoothly, I hope your does too.
here it is today with the rest.

Mrc.

Awesome. Yea the gaskets were really on there. CRC gasket remover for the win.

That stuff peels paint really really well.

[anon3]

Finally started this build too. Matte and gloss black for the cases. L
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[wild200x]

nice so far anon. The second 200x you have ever seen is an 86??? not bad. there are so many more from years previous..

[jasong_10]

Looks great so far. Is that some kind of drying cabinet, or an oven?

[anon3]

nice so far anon. The second 200x you have ever seen is an 86??? not bad. there are so many more from years previous..

Yea, they are super rare over here. Trying to keep this build relatively respectful to the original, just playing with gloss levels and possibly change the blue to cobalt blue.

[anon3]

Looks great so far. Is that some kind of drying cabinet, or an oven?

It’s an environmental chamber at my lab. Really handy for stuff like this.

Using duplicolor engine enamel on this one and I’ve found heating to 75C before coating makes the paint stick really well and speeds up recoat time.

Prime and then back in, out to paint. Lots of thinish coats. After coating I find the flat works better to go straight into another chamber at 105C to dry and bake. Gloss seems to finish nicer by air drying and then baking at 105.

If you air dry the flat it seems to develop a semi gloss kind of look.

Bit more done today. Cases are all done, just baking in. Red bits are the 250r. https://uploads.tapatalk-cdn.com/20210311/cd8598d0c18d17cf1e0bc919519fe3f4.jpg

[wonderboy]

That red look gorgeous! Nice work.

[jasong_10]

That looks great, you'd never know it was rattle can.

[anon3]

Nearly done with painting bits and pieces. Next job is get that f@cking swingarm off the frame.

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[jasong_10]

Still looking good. Know what you mean about the swingarm, it was a 2 person/2 hour job on my R.

[ATC King]

Next job is get that f@cking swingarm off the frame.


For stubborn bolts like that, I put a brass cap over the end and have a go with an air hammer. If it'll move at all, it's going to come out, but may take a little back and forth, some Kroil, and a few days.

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I've got a front fork leg, where the axle is loose, but seized in the spacers to the point I even installed a grease fitting into the spacer and that still wouldn't allow grease under pressure to go through. I've got to save something and it'll be the fork leg, so I'm to the point of cutting the axle to do it, if I can't groove the spacer. I've been at it for months, off and on, with soaking, heat, hammering, but it isn't budging. The worst stuck part I've come across in a while.

[anon3]

F@CK this bolt.

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[anon3]

Got to the point of sealing cases and my Center gasket doesn’t fit. Package is marked 86-87 200x.

Need to order another but how do I know what’s right? This was a namura set.

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[anon3]

Well, ordered another gasket so waiting for that now.

I ended up changing my mind on keeping it stock, I’m building it with more of a blue theme.

Got most of the bits painted now and halfway through the frame. Still need to blast the front hub which seems to be baked hard as.

Shocks will be rebuilt this coming week and hopefully I get my gasket.

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[jasong_10]

It's probably good that you're a world away, because if you were my neighbor I'd go broke hiring you to paint stuff, lol. Nice work.

[anon3]

Haha, the blue one is not great to be honest. I messed up in a couple of places. And I paint outside. It’s.... challenging.

Got the bottom end assembled, and oil cooler connections drilled (streesssssssfulllll).

Back to waiting on parts now. Need oil seals so I can carry on. https://uploads.tapatalk-cdn.com/20210401/5f485a6a1dd50da0b8306f903d346af7.jpg
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[anon3]

New swingarm bolt out of 316 stainless made as well.

The Namura gasket kits being sold on eBay are wrong for 86 in case anyone else is trying to find some. They don’t fit the right hand and Center cases. Got mine from CMSNL instead. https://uploads.tapatalk-cdn.com/20210401/ac676faef73aab1b6e736384c6851322.jpg

[wild200x]

This is going to come out real nice!

[Minter fab]

Very nicely done!!!

[Dirtcrasher]

The 86/87 200X bottom end is pretty strong, the only failures I find are the gear shift plate, and they seem to break allot; Between Shep and I we must have 3 dozen of them :D

Biggest issue is people stripping the LH crank nut on every used crank you find and I never did find a rod that fits, many are just a couple mm's off.

It's looking great, and it's got be hard for you to get parts where you are. You'll be psyched when it's done and nice and tight.

I recently picked up another aftermarket 83/83 250R axle, slides right in the 200X carrier!

LMK if you have trouble finding anything, I know that machine very well....

[anon3]

Thanks, that info on the axle is great to know as I had to literally grind mine to bits during disassembly.

Been looking for an 86 axle but seems cheaper to buy a new dura blue on eBay.

To add to the info on that gasket set the left side cover is also wrong. So just totally incorrect for the year.

Parts are hard to get locally for sure.

Anyone have a complete seat available? That’s the one major bit I didn’t get with it.

[anon3]

The 86/87 200X bottom end is pretty strong, the only failures I find are the gear shift plate, and they seem to break allot; Between Shep and I we must have 3 dozen of them :D


Is it hard to shift? I found the pictures in the service manuals super confusing in the trans pages. Especially with the right and left side cogs on the drive side, which can be put on either way. The pictures show a recess on both sides. Mine are flat on one side and recessed on the other.

The diagrams look deceivingly like they should be the opposite to the actual way they go. At least that’s what I’m thinking.

Once I got it the right way everything is super smooth and low effort.

I’ve got an old 200 as well and I’m sure I’ve got one of those cogs on the wrong way. It’s a bear to shift.

Final pic shows the left gasket being a sh$t left gasket.

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[anon3]

Annnd more parts that don’t actually fit the 86. This time an engine seal kit from vertex.

Clutch lifter fits, that’s about all I’ve found so far.

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[BarnBoy]

Btw, I only run Vesrah gaskets on my hondas. Perfect fit, everything. No messin around with cheap chinese junk. Looks great so far.

Dirtcrasher can probably hook ya up with the oil seals you need, he offers kits for different bikes.

[anon3]

Thanks mate, really struggling with gaskets and oil seals now so I’ll reach out to him. CMNSL is sold out of the left as of now - before I got in.

Also, can someone help me ID this head. Is it a powroll head? The gasket mating surface is machined down from what I can tell.

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[anon3]

Got a little more done on this one. Gaskets finally arrived tonight so I should have the motor in next week.

Back end is all done except I need a disc and the axle anti fade nut if anyone has tips on where to find them. https://uploads.tapatalk-cdn.com/20210423/80ce24b3f13e5dda0f3af2814f967b82.jpg
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[anon3]

Engine in the frame. A few touch ups to do where I hamfisted the install. https://uploads.tapatalk-cdn.com/20210426/acdb9c58b2ab957951f05d711e23534d.jpg
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[patriot1]

Awesome. Great work. Very interesting to watch it come together

[MrConcdid]

Looks great, I never realized how different the 85-86 engine was. Impressive.

[shortline10]

A trx 300ex / 400ex and 400x ani-fade nut will work . Still available new from Honda
Just buy the complete assembly .
And their are plenty of used ones on eBay if your on a budget

https://www.partzilla.com/catalog/honda/atv/2012/trx400x-a-trx400x/rear-wheel-axle-drive-chain

https://www.ebay.com/itm/333969765730?hash=item4dc2263562:g:BCoAAOSwGFdgbMA n

[anon3]

Absolute legend. Thanks.

[Dirtcrasher]

Yep, those seal kits don't fit correctly.

I just got in all my seals the other day, I'll list some in Classifieds at some point. I have every seal for the 2nd gen 200X and the 350X in stock.

I guess you figured out your shift forks? (sorry, very busy lately) but most Hondas have a stamp in the castings - L / R

Coming out great!!

[anon3]

Yep, those seal kits don't fit correctly.

I just got in all my seals the other day, I'll list some in Classifieds at some point. I have every seal for the 2nd gen 200X and the 350X in stock.

Coming out great!!

I got one of your kits on eBay. On its way over now, hopefully be here this week.

Carb coming from Mickey Dunlap as well.

[oldskool83]

TRX250X TRX300EX TRX400EX TRX450R axle lock nuts are all the same and will fit. I personal have never had luck with anti fades. They looks cool as poo but everyone i have had or seen has be worn out. I only run 250R OEM rotor hubs and rotors now. The old durablue posi locks were the best i thought. As of now i run OEM lock nuts but electrical tape them shut. I was told about that trick maybe 13 years ago. Its worked and helped to keep junk out and them come apart stupid easy. Also helps if you invest is a huge adjustable wrench and not a pipe wrench to take them appart.

Hope that helps maybe.

[Dirtcrasher]

Crap, I'm sorry! I haven't been here to check PM's for weeks or I'd have helped.

I can DM you my phone number or Facebook info (if a PM there doesn't cost you like a text message would).

Pretty much anything 2nd gen 200X I have my hands in...

Build looks great!!

PS - Bud, I would NEVER run SS bolts in the 200X cam holder, they will probably be fine but SS is really a cosmetic thing and I don't use it anywhere I worry about needing to be strong or stay tight, it's a weak SS that's used in those fastner kits.

[anon3]

All good, oil seal kit worked a treat.

The stainless is all 316 from my local shop, but point taken.

I received the 300EX axle jam nut from ebay, but it doesn’t fit unfortunately, its a lot bigger than the axle spline and won’t lock down onto the lock ring.


Sent from my iPad using Tapatalk Pro

[anon3]

Bit more done on the backend. Still piecing things together slowly.
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[ironchop]

Looks fantastic

[anon3]

Shock in, oil cooler routed and electrics on. Waiting for the carb and rear wheel lock nut now. https://uploads.tapatalk-cdn.com/20210620/403a695113578e9e7e0459d6ca60d38a.jpghttps://uploads.tapatalk-cdn.com/20210620/1a97910dadc0ba89acf378278aed4864.jpg
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[jasong_10]

Still looking great!

[Dirtcrasher]

We need to make you some frame caps for the back, Shep has the mold. I sold all my NOS ones for 99$ a set! And guys were glad to buy them! I use to give them away at races, at some point I had ordered a couple dozen, wish I had bought/saved more...

Anyhow, hard to match the blue, can probably make up some black ones.

I like all your colors, just enough! Some guys go crazy and powder everything, probably just to keep things rust free though...

What's next?? What do you have left??

[Shep1970]

Um yup i have two blue caps, looks like u need the rear shock rubber too. $10 bucks + whatever the shipping is if your interested in the 2 caps and one rubber. Bike looks good. 267813

shep

[anon3]

We need to make you some frame caps for the back, Shep has the mold. I sold all my NOS ones for 99$ a set! And guys were glad to buy them! I use to give them away at races, at some point I had ordered a couple dozen, wish I had bought/saved more...

Anyhow, hard to match the blue, can probably make up some black ones.

I like all your colors, just enough! Some guys go crazy and powder everything, probably just to keep things rust free though...

What's next?? What do you have left??

Yea, good idea, there’s a bit of wood wedged in one - have to drill that out and coat the inside with a brush.

Left to do, still quite a bit:

Ordered:

Rear wheels and tyres
Plastics

Still to order:

Rear brake slave - bought two Chinese ones, neither fits up.
Front brake master
End caps from Shep
Decal kit
Fuel petcock
Exhaust - might have one made locally - $200 to ship here…

Pending fitment:

Carb and uni-filter
Rear axle jam nut

Work:

Tank is still not stripped, it was painted with some kind of house paint, nothing I covered it with touched it (MEK, MEC) and it’s a bear to get off even with my sand blaster. I look at it sideways daily. Soon it’s time with the big wire wheel will come.

Seat cover is on its way, base is here, just need the foam made once I have everything.

Kickstarter - had to be re-built up in the bore, bushed and more material spun onto the pedal then milled to get a better fit. Waiting on a spring and bearing. Splines are good luckily.

Remake the swingarm bolt, it’s not quite right.

[anon3]

Um yup i have two blue caps, looks like u need the rear shock rubber too. $10 bucks + whatever the shipping is if your interested in the 2 caps and one rubber. Bike looks good. 267813

shep

I’ll PM you, blue is better than nothing, and I can paint them up to match. Rear Shock rubber goes where?

[Shep1970]

I’ll PM you, blue is better than nothing, and I can paint them up to match. Rear Shock rubber goes where?
It covers the lower dial area/ keeps mud and dirt out 267819
got your pm- i"ll pm u back tomorrow

shep

[Dirtcrasher]

I have NOS 3wheeler masters just like what came on the 250R/350X and 2nd gen 200X, they have the oval head JIS screws.

I do have regular newer style complete masters as well, they use a SHCS or hex bolt but all are OEM NOS Nissan masters from Honda years ago, not 18$ China masters.

I sold allot of them on Ebay but can do better privately.

There are a few OEM rear masters that fit as well, I'd have to look at my notes.

But some don't even have a reservoir which I love because I'm always trying to route a big fat exhaust thru that subframe and it's a tight fit...

PS - Put a dab of silicone on the frame plugs, it's not Sheps issue, right from the factory they were too loose and his molds are based off of OEM parts.

[ATC200X4716]

Nice looking restoration! Just so you all know I'm working on reproduction 86 200x kick starters. Almost have them done.

[Dirtcrasher]

Are you making them out of aluminum?? That was the only way I could go about it...

[ATC200X4716]

I'm making them from 17-4 stainless. They will never corrode. They are sweet....i'm just fine tuning the return "click".

[Dirtcrasher]

I'm making them from 17-4 stainless. They will never corrode. They are sweet....i'm just fine tuning the return "click".

How did you "broach" your splines?? I made a cutter from an old shaft but I'd need a longer shaft to slowly increase in size to cut them in steel, works in aluminum though...

[ATC200X4716]

I had to make a tool to broach the splines, especially since I am cutting steel.

[anon3]

Kicker I managed to get my neighbour to sort for me. Built it up and milled it back. So close to the first start now.

Tank will be done this week and then it’s time to see it start. https://uploads.tapatalk-cdn.com/20210813/a6ba2d735228263945f3d89ba727c02e.jpg

[jasong_10]

That looks awesome, nice work.

[anon3]

Got my tank on finally. Seat should be here this next week. Plastics are almost in the country. https://uploads.tapatalk-cdn.com/20210903/49dba50f9db1daf6bb55312816954658.jpg

[jasong_10]

Still looking good, what color plastics are you going with?

[anon3]

Finally Finished this one, mainly.
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[jasong_10]

Nice work, looks great!