242x Build Thread

[Berger83]

Howdy, I have been a long time creeper on the boards here and I am well underway into my current build so I figured I might as well start a build thread. Currently this project is just called 242x as that will be the final CC's, so anybody with some good name suggestions are welcome. This started off as a pretty nice 1985 200x with a bad motor (smoked like a freight train). My dad and I had a couple brilliant ideas that involved the new CRF230 motors. Instead of doing the entire motor swap (what fun is that) we decided we were going to build a new trail rider with some updated CRF internals. So about a month and a half ago i completely stripped the wheeler and tore the motor down to just the cases. We didn't entirely know how we were going to put the new bike goods in there, but we were going to do it somehow. Here is how the wheeler started out.

[Berger83]

Now that the wheeler was stripped, I could start gusseting the frame. I knew the early 200x's had problems cracking by the down tube, so I cut and had my dad weld a gusset there as well as fill in the triangular piece right underneath the front of the motor.

Bare frame:


Making of the gussets:






And the finished product:

[Berger83]

I knew that since I was building a new trail rider that I wanted more suspension. So I ordered a set of 1984 250r forks and triples off of eBay and had the triples drilled to fit the 200x stem. One of the forks had a slight bend in it so I disassembled both, put them on V-Blocks and made sure they were both straight by pressing them into shape. I rebuilt the forks and used some progressive springs from Progressive Suspension. As for the rear, I also ordered an 83 250r rear shock.

Straightening the forks, the new springs, and the jig we made to press them:

[3R Better]

I like it i had to redo my frame due to rust.