XR Parts question (Turning into my 200x rebuild)

[coldfuzion76]

Found a 95 xr200 that I'm going to go get this weekend, just for the motor. Plan on putting just about all of it on my '84 200x. I plan on boring my cylinder for the piston for the larger cooling fins, but leaving pretty much everything else the way it is. My question is, will the decompression lever on the xr kick shaft fit the one from my 200x, or will I have to use a manual setup once I put my kickstart in there? I'm not really even for sure how that all works, as I don't have it here and apart yet....

[scooterroo]

didnt know the 84 200x had a decompression lever, my 85 didnt, and the one i have sitting behind the garage doesnt.

[coldfuzion76]

Was wanting to use the automatic one on the XR200 motor, but I FINALLY found a manual for it, and figured out I couldn't. It's part of the sidecover that I can't use. :(

[Erics350x]

It should be the same bore unless its been rebuilt and if your X has been bored the xr piston will be too small. Your better off using the xr cylinder.

[AutoXer]

No use the X jug it has larger cooling fins. You will need to bore .50 over to use the xr piston as the stock bore is 65.5 in the xr and 65 in the 200x the xr has a higher compression as well as a slightly bigger cam then just get the kicker to go forward and you are good . Maybe use a 10.25:1 wiseco piston? I wouldn't worry about the decompression deal shouldn't be a problem

[coldfuzion76]

Yeah, kinda disappointed about the decompression thing, but I figure if I back-cut my gears I should be ok. It's already not the greatest. Just kinda nervous I'll screw them up. Anybody out there do that for $$$$?

I was planning on using the 200x cylinder for exactly the reason stated, I want the larger cooling fins. May not really matter, but I also don't know for 100% what the other cylinder looks like either. But it's supposed to have good compression, so at least the piston should be ok, and with a fresh bore, some rings, and new gaskets and seals, I'll be much better off than the smokey thing I have now.

[Erics350x]

I was wrong the xr is a larger bore. I dont know why i was thinking they where the same.

[AutoXer]

keep us updated on this it is a great swap that really hasen't been covered that much. You will be getting some great upgrades ie bigger carb/cam and a 6 speed very cool

[coldfuzion76]

Yeah, I'll keep you guys up to date on it as I can. I go get the bike on saturday, and I'll start tearing it down probably that day. Also kinda interested to see what else may fit, if anything. Keep hearing about using the xr parts in the stock engine on here, but I'm pretty much only gonna use the cylinder and kickstart/sidecover from my 200x. Can't wait to start playing with it!

[coldfuzion76]

Made it home with the xr200... Really a piece of crap, glad I just want it for motor parts. Hopefully I can sell off enough on fleabay to pay for some of this... Anyway, got the motor out, and I got the top end apart. Looks pretty decent for what it is, cylinder will actually be reusable on a later project. (Gonna build a motor from the leftover parts for a go kart :twisted: :twisted: :twisted: ) Only problem is the cam is shot. There are several grooves where it and the bearing meat in the head. :( Hopefully I can find another before it all goes back together. We'll find out more when I get the bottom half apart. KNEW I should have bought a flywheel puller earlier....

[jenndnn3]

you can use the 200es flip-up decompression lever along with its rockers.

I highly recommend this as we all know the kicker system is "weak" to begin with and you are about to put more stress on it..

Take a look at 84 200es on bikebandit.

I simply used the the 200x kicker system in the xr engine with the 200x outer covers and some odds and ends..

The number one mistake I see with this is you must match the gears with the kicker start gear internally. 200x must match 200x after that your in the clear.

[coldfuzion76]

I was planning on using my old park brake cable, like on saw on here somewhere that someone did for use with the goki electric start. Once I get everything apart, I'm gonna use my 200x kicker, back cut the gears, and use whichever spring I think is stiffer.

You said you used the xr engine, did you use the cylinder as well? After I'm looking at it, the fins aren't really that much smaller, and it's not like I'm gonna race this thing. READ: (I'm getting cheap and/or lazy)

[AutoXer]

a axle will work to pull the flywheel if you don't want to get the puller

[coldfuzion76]

You mean like the front axle? Ok, duh, but didn't realize this... wonder if that xr is the same, so I don't have to use the one off my trike just yet.....

[AutoXer]

actually i used the rear axle ..... a swing arm bolt will also work

[coldfuzion76]

Tried the front axle from the xr, and it's too small. Taking it apart to sell it off anyway, so I may try the swingarm bolt. Just trying to do as much as I can before I start taking the trike apart is all. Gonna try and hit some hardware stores tomorrow before work. Most of them suck around here, though.

[jenndnn3]

Yes pretty much everything except electronics kicker system and some other things were all xr..and the stuff that you can keep the same life is just easier. Especially at the parts counter :D.

When you go to compare the engines you will be very pleasantly surprised just how much interchanges..

Now I think you got a newer engine then one I used. So some ticky tacky stuff may be slightly different.

[adamd]

i have the posibility to buy a 87xr200r for 100 bucks runs but needs a crank bearing would it be worth i for the parts for my 200x tranny and topend are good cranks about shot n bike aint very perty but ridable proly sell off most the bike how hard is it to make the 200x 6 geard im not great at bottem end work but my girl frinds brother n dad have rebuilt 1000s of motors

[coldfuzion76]

for a hundred bucks I'd buy it. The top end is where it gets all it's power upgrades, and the 6 speed should just swap right out. Go look on ebay for an xr200r carb. most of them go for $50 or more. Or you can use the crank from the 200x in the xr case with the 200x side covers, or just mix and match... Possibilities are endless.

[adamd]

ok thats what i thought then got the idea to look n see if crank bearings swaped cas i have a good set on a bad crank, everythings there to put the dirtbike togther what mm carbs a xr 26? i have a 28mm mikuni that be nice on this bike
and then put the 26 on my stock bike if i wanted

[coldfuzion76]

Just a little update on where I'm at. As I said earlier, I got part of the motor tore down, and the cam is smoked. I tried to get pics, but you really couldn't see the damage. The rear bearing surface and the bearing itself have nice long score marks all across them, and the lobes have worn down visibly.

***GOOD REASON TO BE CAREFUL WITH RTV/SILICONE.****

Turns out the moronus anonymous (the idiot that put a new top end on the motor even before the guy I got it from) used silicone and no gasket at all on the rocker cover. He blocked the oil feed going to the cam with a nice big glob. IDIOT! It's really a good thing the cdi pickup went bad in the bike when it did. Saved the rest of the head and rockers at least.

So now I'm on the hunt for a new cam. Found a cheapie on ebay, and I'm thinking REAL hard about getting it and sending it to webcams, along with my rockers......:twisted:

[AutoXer]

there is no gasket for the rocker cover and it is real easy to get too much sealer on there fyi

[coldfuzion76]

Glad you told me that. I'd have been upset. lol. Shoulda seen this thing, though. Wish I had taken pics as I was takin it apart. He must have cleaned off the outside after it all squeezed out, but there was a mess inside.

[Dirtcrasher]

No gasket X2

Thats why I use the Threebond, it's so much easier to deal with and seals excellent.

Don't forget, that one oil orifice you see on top at the end of where the cam sits is supposed to be blocked and is merely there from Honda machining the oil gallery. They have a rubber plug thats made for that opening.

If you look long and hard at all the parts, you'll figure out how the oil gets to everything.

Those are the 2 mistakes people make - no plug during assembly or too much gasket sealer and in the wrong place.

Post up some big clear pics if you can.

Low or old oil does just as much damage though........

[coldfuzion76]

Ok, I don't have pics just at the moment, but there was no oil plug where it's supposed to be. There was a LOT of silicone on the inside there however, including where the plug would be. I'm guessing that this is what caused the damage. I'll have to look at it again later. It looked like the front of the cam, towards the cdi, was getting oil, but not the other, but I could be wrong about that. The front surface wasn't damaged, just the rear that rides in the bushing, and the closest lobe.

[coldfuzion76]

Ok, been slow to update, but I'm pretty broke after being unemployed for a while, and just got a new job, so I gotta be slow. Didn't want to take the trike motor apart until I went to change them, but I'm going to have to as I can't really afford not to.

Finally found a crank puller with the rear axle of the xr. Worked really slick, gotta keep that thing around! So I got the case split, and everything's looking really good aside from the dirt. So I felt kinda froggy and decided to try my hand at back cutting the kickstarter gears. Was a lot easier than I thought!

http://i44.tinypic.com/149v19w.jpg

Still got a little filing to do, but I'm gonna take it to work for that. We have a lot better files than I do here at home. Gonna get this thing cleaned up in the next few nights, and hopefully start tearing down the trike motor soon!

[greenhuman]

Must be a clever person who thought of cutting back the kickstarter gears! That will NEVER slip again.

[coldfuzion76]

Must be a clever person who thought of cutting back the kickstarter gears! That will NEVER slip again.

Yeah, I was a little scared to try it myself, but a little time with a dremel, and I think they turned out decent. You're awesome, man!:w00t:

[coldfuzion76]

OK, so I know it's been almost a year since I've done anything on my trike, or on here, but I finally got all the other crap out of the way, and have been able to start again. So I've learned a few things that may be worth mentioning. I got my stock motor out this morning, after trying unsuccessfully to get the XR motor back together, as it been a long time since I had taken it apart. Lol. Turns out I had the kickstart idler gear on the main shaft. OOPS. But now that I have both motors aparts I thought I'd share a few things. First, the flywheel on the XR motor needs a bigger bolt to pull it than the 200x motor. I used the rear axle from the bike to pull it, and the swingarm bolt to pull the one from the 200x. Weird, but that's how it worked. I think the best bet for this is to just use the complete bottom end from the XR, and just cut it's kickstart gears. You HAVE to use them, the ones from the 200x won't line up. Just transfer them over to the 200x shaft. Also, I found that the clutch side crank bearing is bigger than the one in the 200x, and will not fit in that side of the case.
All of this may have been mentioned somewhere else, but it's just what I've figured out today. I've decided to just use the complete XR bottom end again, now that I know how it goes together, and could have saved a little time not taking the other motor completely apart.