Enough parts came in and I was able to get the engine back together. Still waiting on a couple carb parts but it’s pretty much ready to go back in the bike!
I watch these rebuilds all the time. Never know if you will see something interesting. I have used a couple of pieces of wood to hold the piston up high and stable while trying to fit the cylinder.
Great top end rebuild , be good to hear it run after this . I remember doing the valve lapping on my old xl 250 years ago , quite awkward to get the wee collets on the springs .Good job .👍
Nice work on the build. I'm almost finished rebuilding a 1987 XR200R, just some carb tuning remaining. Don't forget to set the firing timing (the second line on the flywheel) with the position of the CDI, but maybe you plan to do that once you get the motor in the bike. Anyway, I look forward to seeing the next video.
Thank you! I actually do need to do that yet. I had to piece the CDI stuff on just to wrap up the video because I’m still waiting on a couple gaskets for it that got lost in the mail 😡. Didn’t want to delay the video any longer than it already was. I appreciate the heads up!
Got it on eBay. Here’s the link. The factory Honda workshop manuals are ridiculously priced. www.ebay.com/itm/265337507604?mkcid=16&mkevt=1&mkrid=711-127632-2357-0&ssspo=VOMvm8qcQXO&sssrc=4429486&ssuid=1QWenE7CT8u&var=&widget_ver=artemis&media=COPY
hi, i'm busy with an '82 restore so your video is a tremendous help, thanks. One question.. at 34.07 on your video there is a shot of the top and on the left of the shot is a small hole? in the body of the cover opposite the end of the cam, i've read somewhere that there is a small rubber stopper type part that goes in there..? can anyone clarify this..? mine didn't have one when i opened it up so had to order one.. cheers
Glad the video is helping out! There is a little rubber bung that sits down in there. I can’t recall at the moment what that’s for but there should be be one there in that spot.
@@Garage2Trail Thanks for the reply. Even with the pickup clocked all of the way to the right I can’t get it to align with the advance unit. TDC been checked 3 times, I can’t figure it out. I even moved the cam gear a tooth each way but “T” would not align with cam gear mark.
@@csedan510 hmm, I wonder if your advance unit is out of another 200 motor weather it be the ATC model or perhaps a different year XR200 that may have been different. I can’t say I’ve done enough to know for sure. I recently picked up an ‘83 XR200R so I’ll probably be getting into this again.
@@Garage2Trail it was working and oriented properly when I took it apart or so says the old screw marks on the base plate. I’m got to check flywheel and make sure key isn’t broken.
@andrewYdoesntAnyHandleWork the feeler gauges I use are old Craftsman’s that my dad gave me…sorry I don’t have a link to those lol. I’m sure any on Amazon with good reviews would work though.
@@andrewYdoesntAnyHandleWork hi Andrew! The book I have shows 20-22 ft. lb.(240-264 in. lb) on the accorn nuts, and 6-9 ft lb(72-108 in. lb) on the allen bolts
Have question i bought a roller,1998 xr 200 r honda the bottom end is good it moves,but it didn't come with a piston,so i ordered piston kit on ebay brand new ,but the connecting rod thatbwas left in there is not pushing the piston up far enough,what to do,NOTE : THE KIT I ORDERD WAS BIGGER 250,. SO DO I NEED GET ANOTHER CONNECTING ROD AND IF I DO TJAT WILL I HAVE TO CHANGE THE CRANK ALSO? HOPE TO HER FROM YOU?
Was it a “big bore” kit specific for the XR200? Its tough to give a definitive answer when there are mix matched parts unfortunately. I’d hate to give you bad info and have it cause damage to your bike.
Not sure…everything I’ve rebuilt has been back to stock specs so I probably won’t be much help. Sorry! I’m always worried about aftermarket stuff fitting correctly. Does the kit mention anything about a connecting rod? Maybe it was for the CRF230? Just a guess tho
@@Garage2Trail no it didn't say nothing about that ,but could you send me the actual size of the original poison for the Honda XR 200 r, like 66.50 or whatever it is called? Maybe if I get that I can move forward
@@johnmathewson985 ok yeah, I marked mine but let me check the manual to see if they make note of any factory timing marks. When I got it back together, it ran perfect so I didn’t change anything. I’ll get back at ya…
Ok looking at the manual, it says to set the timing marks on the flywheel to “F” with the index marker on the top of the hole on the side cover. Then install the base plate aligning the index mark on the pulse coil (small black box that has the shielded wire coming out) with the mark on the rotor. Basically two vertical lines….so I guess really you need to make sure you got that rotor on the right way while at “F” on the flywheel before worrying about the baseplate. Hope that helps. Kinda hard without pictures to explain.
Believe it or not, but the rear axle bolt is what I used. The threads are the same. Just make sure they are cleaned up and good before cranking down into the flywheel so you don’t booger those up.
@@snorkelmancraig2740 lol…I didn’t know until I saw someone mention it on a Facebook XR page. mine is a 2002 but I think the axle is the same on a lot of years.
I wonder if that’s attributing to the little bit of noise I hear just above idle. It goes away when the revs climb and you only hear it for a second when the rpm drops down. When it hits idle speed again you don’t hear it. I’ve double checked the cam chain tension because that was my first thought as it sounded a bit like chain rattle but that’s tight. I adjusted the valves too and they are spot on. Bike starts easy hot and cold and doesn’t smoke so I haven’t been worrying too much about it. Been riding it a lot too.
@@Garage2Trail changing my cam chain slack at the moment, oil filter etc. but not a xr200 it’s a cxr200 😂 its a 86cr with a xr200 in it. But I’ve used this vid for valve lash as well.
@@snorkelmancraig2740 for the valve cover I just used some permatex black gasket maker. For the moving bits you’ll want to use assembly lube or just liberal amounts of oil