tlr200 motor in a 200s PICS! UP AND RUNNING!

[hondahaulic]

Well my 200s has needed a rebuild for a while, but I figured why rebuild it when I could buy something a little better? I have never really liked the pullstart and I would rather have a manual clutch than an auto, so I ended up buying this a few minutes ago: http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=260203061482

Its a tlr200 honda motor from an older trials dirtbike. It should bolt right in, right? I'm hoping to use all the wiring and components from the 200s along with the carb and exhaust (until I upgrade them, hopefully soon). Does anybody see any problems I might have getting this motor running in my 200s?

[atctim]

The TLR motor is almost identical to an XR200 motor - The exhaust and carb are way different. I'm sure you can make it work - but you have a reverse kick start with the TLR motor - not sure how you would do that and keep the 200S bolted on fenders.

Here is a pic of the wife's TLR
http://www.venustel.com/~tkeister/reflex2.jpg

[hondahaulic]

I already knew the issue of the rear kicker and im not too worried about that, but do the exhaust and carb attach differently? I'm aware that using the 200s exhaust and carb will be a downgrade until I buy a better system(83-85 200x??), but they will still bolt on and function properly?

[hondahaulic]

also, does anyone know what other kick start levers will fit this motor? Im guessing one from an xr200 will work, but are there others?

[hondahaulic]

i did notice that it looks like this motor doesnt have the pulse generator on the end of the camshaft. will this create a problem if i try using the 200s harness? what will i do with the 2 wires?

[Jason T]

The TLR engine is a detuned xr engine. You get the advantage of the 6 speed gearbox, but the TLR only makes about 12hp compared to 19hp with the XR.
However the TLR engine makes the same torque as the XR engine, but at much lower revs. This makes it a nice engine for climbing hills etc, like the TLR was intended to do!!;)
The pulse generator in the TLR engine is located in the flywheel cover, so the two wires should come out of the flywheel area rather than the side of the head like your original engine.
The TLR uses a very small carb, to go with the very small valves and inlet side of the head. So your 200s carb will be a bit of an upgrade:beer


Jason

[hondahaulic]

oh ok thats good to know the the pulse generator won't be an issue. If I'm not satisfied with the power I might experiment with my 200s head on the motor, or possibly be on the lookout for an xr200 head, valves, and cam.

[Jason T]

The TLR engine will have more torque than your 200s engine, and the power will be similar as well.
If you want XR power you will need to change the head,cam,piston and carb.;)

Jason

[hondahaulic]

well, when i got home from school today the motor was finally here. 2 hours later I had new rear axle bearings in and the motor bolted in.

[hondahaulic]

i ran out of time to work on it tonight, i still have to hook up the wiring, exhaust, clutch cable, chain, and figure out a kicker. that should be about all it needs.

[hondahaulic]

well i did some more work on it tonight. i got the wiring hooked up and it has good spark now. I put a clutch cable on and got the chain and exhaust figured out too.

The kicker seems like it might cause a little bit of a problem, all i could find for a kicker laying around was from an old CB motorcyle and it hits the rear tire when I try to kick it. I'm not sure if its because its longer than a stock kicker, but the kicker would have to be quite a bit shorter in order to clear it. Is there anyway I could could use parts from a 200x motor and easily convert it to a forward kicker?

[200x Basket]

you can convert it but you will have to split the case. I would sell that and get a 200x engine. way easier.

[hondahaulic]

Would I need to really dig into it and switch alot of parts over from a 200x bottom end, or would I be able to get at everything I need by taking off the right side crankcase cover, and then slapping on a 200x right side cover and kicker internals? I would really like to use this engine if I can. Howbout adapting my 200s pullstart to the left side?(just thinking out loud)

[200x Basket]

you would have to split the center case to use teh 200x kicker. I really do not see why you would prefer that engine over a 200x. stock VS stock, the 200x would spank that engine in every way.

[hondahaulic]

ok, that ideas probably out then. I know a 200x would be alot better choice, but the tlr is what Iv'e got and i doubt i could sell it and get a 200x motor without losing a good amount of money. Although the extra power would be nice, I doubt I need it in this hard tail.

[hondahaulic]

Well I haven't had much time to work on it for a while, but it got warm today so me and a buddy got it fired up. This thing runs awesome with tons of low end power. I was also surprised with the top speed, it definately feels like its faster now than before. It tops out at ROUGHLY 55-60 (my snowmobile running right beside it) and I think this is mostly because its a 6 speed instead of 5.

[MADATC]

:pics: :pics: :pics: :pics: :pics: :pics: :pics: :pics:
In case you didn't know.

[hondahaulic]

well heres some pics, its dark and cold outside so this is the best i can get for now.

[hondahaulic]

I still haven't figured out how i'm gonna start this thing, for now I have just been bump starting it or pulling it with my snowmobile. My plan is to try and get the recoil starter from the 200s motor onto the tlr motor. By the looks of it, this just might work if I swap the flywheel housings.

In order to get the housing off of the 200s motor, I need to remove the flywheel (4th pic). Do I need one of those flywheel pulling bolts for this, or is this a different type of flywheel? How do I get the thing off?

[McDerry]

Whats interfering with just using the kicker??

[factoryX]

no kick start lever...

[84honda200s]

you can convert it but you will have to split the case. I would sell that and get a 200x engine. way easier.



agreed


either a 200x motor or stick a 200x top end on your 200s bottom end. hell or just put a 200x piston and rings in your motor with a 200x cam. the 200s and 200x are much alike in many ways. well engine wise anyway.

[hondahaulic]

Well I got some more work done on it, I made a shorter kicker today that clears the tire. Its a pretty stubby kicker, but with the automatic decompression adjusted correctly I'm hoping it will work. I couldn't quite get it to start with the short kicker tonight, but I'm hoping it will work once its not so cold (its around 15* right now). Anybody got any other ideas, other than finding a different engine?

Also, I got the front sprocket guard on tonight. The 200s guard fits great after some grinding. I'll try to get pics of the guard and my kick start lever tomorrow.

[McDerry]

Got a wedler, a couple bolts, some small pipe

Could mount a second pivot on the frame behind the location of the kicker shaft on the bike motor. Then you make a new kick lever from that pivot. At equal distances on the lever from the new pivot and the old kick lever on the bike you make a mount and runa linkage between the two.

Its like forward controls on a old harley

[hondahaulic]

Wow, that linkage setup looks like it would work perfect for what I need! I was actually thinking of doing some kind of external linkage on it to move the kicker forward, but I was drawing a blank. This setup looks like it should solve my problems!