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screwtape
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Date Posted:09/01/2012 9:48 PMCopy HTML

Hey guys,

This will probably be a pretty picture heavy thread, so prepare yourself!

I acquired this 1983 XL200r a few months ago. It has about 900 original miles on it but I believe it has been sitting since the '80s... 



This is going to be a budget rebuild, and a learning experience for me. Ive done a bit of wrenching on newer bikes, but never done any motor work or rebuilt any older bikes. The plan is to get it up and running and looking good again, and maybe make a few improvements. Im hoping to make it a bit more like an XR at least in the looks department if nothing else!

Lots more to come!


screwtape #1
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:09/02/2012 6:16 AMCopy HTML

Made some progress. If i ever get a day off Ill be able to make some real progress, until then it'll be just a little bit at a time.

screwtape #2
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:09/02/2012 6:21 AMCopy HTML

 I need to have a key made, or order a whole new ignition. I read somewhere on the site that there should be a number stamped on the starter, and I can take that number to a locksmith to have a key made. If anyone has more info on this please share.

Also I will definitely be replacing the exhaust can. It doesn't look like anyone makes an exhaust for this model so If anyone has suggestions as to what other models exhaust may be a close fit that would be really helpful.
Swiss #3
  • Rank:Diamond Member
  • Posts:1254
  • From:USA

Re:New to me XL200r build

Date Posted:09/02/2012 11:19 AMCopy HTML

This is the 2-valve engine so it would normally fit in the same category as the SL/XL125.  The Category should be 125/185/200.


Swiss

screwtape #4
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:09/03/2012 8:47 AMCopy HTML

Got a bit more done before work today.

Ive been looking online a bit also and the XR200r exhaust looks like its generally the same size and shape as the XL so i may be able to use that. Im thinking either that or possible a universal megaphone style exhaust I would have to make a mid pipe for it though, so well see.
motor_head #5
  • Rank:Silver Member
  • Posts:84
  • From:USA

Re:New to me XL200r build

Date Posted:09/03/2012 3:03 PMCopy HTML

Regarding that key.......you should have a code stamped on the ignition. Usually four digits. Then you visit Hondakeys.com. It's operated by a guy named Mark Troxxel. Super guy. Chances are he will have a key to fit your ignition. Good luck with the build.
screwtape #6
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:09/04/2012 8:23 AMCopy HTML

Reply to motor_head (09/03/2012 09:03)

Regarding that key.......you should have a code stamped on the ignition. Usually four digits. Then you visit Hondakeys.com. It's operated by a guy named Mark Troxxel. Super guy. Chances are he will have a key to fit your ignition. Good luck with the build.

Oh cool, Ill check that out! Thanks!

Pulled the motor tonight after work and degreased it a bit.

The plan is to strip the paint off  of the motor while its still assembled then disassemble it, clean and prep the individual pieces(case covers, cylinder, etc.), paint them and then reassemble with new gaskets and what ever else it may need.

Im also throwing this around as an idea for the headlight. What do you think? At this point I think its either this or ill modify an oval number plate to go above the stock light.

screwtape #7
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:09/13/2012 6:33 AMCopy HTML

Reply to motor_head (09/03/2012 09:03)

Regarding that key.......you should have a code stamped on the ignition. Usually four digits. Then you visit Hondakeys.com. It's operated by a guy named Mark Troxxel. Super guy. Chances are he will have a key to fit your ignition. Good luck with the build.

I contacted hondakeys.com and unfortunately he does not have that key...smiley3

Looks like ill be taking the ignition to a locksmith.

Bought a compressor and Im in the process of sandblasting the frame and motor. Progress is slow but steady.



jitterymonkey #8
  • Rank:Gold Member
  • Posts:118
  • From:USA

Re:New to me XL200r build

Date Posted:09/13/2012 6:41 AMCopy HTML

 Hey ST, 

Really like your 200.  My 1st motorcycle was a '83 XL250. 
(should have never sold it.)

I don't know why your having trouble getting a key made.
The local Honda dealer had one for my '72. 
Can't imagine why you couldn't get one from your dealer.
OZ_Sparklz #9
  • Rank:Diamond Member
  • Posts:1714
  • From:Australia

Re:New to me XL200r build

Date Posted:09/13/2012 3:15 PMCopy HTML

G'day ST ... re:  Post # 2 & 7 ... & keys ... have you had a look @ this thread? 

http://forum1.aimoo.com/XLBoard/categroy/Topic-1-2214813.html#NickName_5321484

Cheerz OZ 
screwtape #10
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:01/24/2013 5:05 AMCopy HTML

Hey guys, I know its been a while but I've just been too busy to work on the lil XL. I finally got some time and got back to work though so I have a few small updates.

Finished sandblasting the frame and motor. It was a nightmare... I dont think I will sandblast anything ever again. At least not without a proper set-up. It didnt work great, but it took off the majority of the paint and the surface rust.



screwtape #11
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:01/24/2013 5:14 AMCopy HTML

I also went to work on the forks. They were fairly corroded and stained but with enough sandpaper and time I got them looking decent again.


screwtape #12
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:01/24/2013 5:25 AMCopy HTML

Also got the motor apart which should've been easy except that everything was very very stuck. Eventually with enough liquid wrench, an impact driver and many many smacks with a dead-blow.


screwtape #13
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:11/30/2013 5:51 AMCopy HTML

WOW! Its been almost a year since I last posted in here! Progress has been slow. Between work, school, and running 2 race series this year, I didn't have much time for the XL. As soon as the season ended though i got back to work.

Refreshed and repainted the motor a few months ago.



Repainted the frame and swingarm last week.



New fork seals and 15wt oil.



Cleaned up the rear shock, removed the rust and repainted the spring.







Next thing on the list is put the motor back into the frame. Clean up the wheels and bearings and order some new rubber!



lakisman46 #14
  • Rank:XL Board Member
  • Posts:2
  • From:USA

Re:New to me XL200r build

Date Posted:05/14/2014 11:51 AMCopy HTML

Very good job.
screwtape #15
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:09/09/2014 12:13 AMCopy HTML

Jeez, nearly another year gone by since ive posted an update. Life has been crazy progress has been very slow. We'll Ill cut to the chase. Motor has been in the frame for a long time now. The bike is running but still needs new tires, chain and sprocket etc which I'll be ordering this week. wheels took forever to clean up. had to clean every spoke... smiley49The stock exhaust was hideous and had apparently become a nest for some sort of animal... As this bike is on an extreme budget I decided to chop off the stock exhaust can and run a sort of shorty straight pipe set up for now. I may weld up an exhaust for it at some point tho. The airbox and all unnecessary BS has been deleted and replaced with a small aluminum battery box for the Lithium 4 cell battery. I Just finished wiring up the new tail light and turn signals today as well as replacing a faulty blinker relay. Ill post pics of that when I have the wiring all tidied up.

no idea why these pics came out gigantic... haha Stock pegs replaced with XR100r pegs. They fit with a little drilling and some spacers.


trimmed the rear fender and added a number plate. and had a ton of rust in the tank so I had to use electrolysis and then a rust removing agent afterwards.


screwtape #16
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:09/22/2014 4:12 AMCopy HTML


New chain and sprockets (now 13t fr, 50t r), tires and tubes. Rode the bike for the first time today! Fueling is terrible... I ordered some main jets so thats a start. Ill also need a new chain slider and have to figure out what to do about side number plates as well as whether or not I ant a front fender...
screwtape #17
  • Rank:XL Board Member
  • Posts:19
  • From:USA

Re:New to me XL200r build

Date Posted:09/23/2014 5:07 AMCopy HTML

Took a look at the carb today and ran into a bit of a snag. According to my manual the jet needle is supposed to have 5 clip settings. The only problem is that it doesnt. It has just one, so i cant adjust it. Maybe the CA model is different? Also the main jets I ordered which are supposed to be for the "PD" series Keihin carbs are not the same style as the OE main jet. The OE one is a very short slot head style jet whereas the others are much taller hex style head jets. The threads are the same however and the new jets physically fit inside the carb, I'm just not sure if the height will have any adverse effects... Whats frustrating about this bike is that since there were very few made there are simply no parts anywhere to order for it. smiley44

Anyway before I start getting any of that worked out I thought I should fix the exhaust situation so I'll be chopping up one of my old stock cans and getting it to fit. Hopefully that gets it a little closer to running decently.

To be continued...



Go soothingly on the grease mud ... as there lies the skid demon! ...






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