Update on 200es

[jdtench]

This is my 1984 Honda 200es. My dad bought it new back in 1983. It has been through hell and I've spent the last 3 weeks working on it. So far, I've...
1) rebuilt the top end. Piston was locked up.
2) rebuilt the carburetor. (By the way, I have a chinese carb bought from Wincycles if anyone wants it. It ran great with it, but I wanted to keep it original, so I rebuilt the original.)
3) grinded, sanded, primed, and painted the rear rack, hitch, skid plate, rear axle, rear hubs, rear wheels and rings, and entire frame. (I know, I got overspray on the tires. Need to get out the pressure washer!)

This is where I am so far. I am still going to sand and paint the gas tank. I want to get the seat covered. I still need to remove the front wheel, sand, prime, and paint it. Install new bearings and dust seals. I also need to figure out what to do about fork boots. I looked them up, they are $33 each before shipping. Right now, there's a roll of black duct tape on them from when I rebuilt the atc 14 years ago. I may just do that again. I think trying to get the suspension working is a lost cause. Any suggestions on aftermarket fork boots that won't break the bank?

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[kb0nly]

Sweet! I have an 84 200ES as well that i love.. I got it in such a nice shape that i have been babying it, fixing this and that and putting stuff back to original, but i agree on the fork boots! I got a new set from www.denniskirk.com

Daystar Series 58 Fork Boots
Part #58626

They worked great and look good! I can get you a picture if you want to see the finished install of them. I plan on getting a couple new bands for the top end, mine are rusted and pretty thin and fragile but holding for now. The bottom end is just held in place with the two cable ties included with the boots, they really aren't needed as the bottom end sits pretty snug but i put them on anyway.

The only trick to installing these is getting the top over the bolt that holds the shock. Its a tight fit, i sprayed the fork and the inside of the boot with some armor all to get it slippery and then used a plastic shoe horn to work the sides up over the head of the bolt and the nut, it turned out really nice though and they look great! Best part, only $16.99 per pair!

[jdtench]

Thanks! I've been contemplating what to do about the fork boots and I can definitely do $16.99 for both of them. Just wasn't going to spend $66 on them. I'll get them ordered and hopefully they'll be in for the weekend.

I've been kinda doing the same thing. I wanted to get the core stuff done and then just tinker with the rest. Like the tail light frame. I know it is rusted bad, but I can always remove it later. I'll work on the front end next week.

[jdtench]

Ok, got the gas tank pretty much done. Just put the third coat of clear on it. here's how it came out.

http://i1240.photobucket.com/albums/gg488/jdtench/GasTank2.jpg
http://i1240.photobucket.com/albums/gg488/jdtench/GasTank.jpg

I also removed the front tire. MAN, WAS THAT A PAIN! I've read on here the trouble people have with removing that axle. I just had no idea it would be that hard. I was using a 5 lb. hammer and a brass bar for over an hour before it started to move. I also found why my suspension was froze up. It was packed with grit, grease, and I think some mud! I plan on cleaning that out real good and greasing it up so I have some suspension. The fork boots did come in as well as new bearings and seals. I'll get the wheel and hub sanded down, primed, and painted soon. I also shipped my seat off to Cosmic Quads to get it re-covered. Hopefully I'll have it before its maiden voyage on July 15th.

Any suggestions on what I can do extra when reassembling the front wheel, axle, bearings, seals, and suspension so I don't have such a darn difficult time next time I have to remove the axle?

[kb0nly]

Tank looks nice! And man that sucks on the axle, i pulled mine and it came right out, all i did was pull the cotter pin and spin the nut off and put a block of wood on the end of the axle and two hits and it came right out while spinning it with a screwdriver through the hole in the head of the axle.

As for putting it back on, grease grease grease!! Clean out every hole the axle passes through and grease them, grease the axle too. I got one that was bad, a 185, a while back with a flat front tire that wouldn't hold air but looked good otherwise, it was a bad valve stem that was cracked through. We pounded and pounded and cussed and yelled at it, finally came out. I ran a plumbers brush through the axle hole on both sides and coated everything in grease, then i slid the axle in after greasing that as well, i had a greasy mess but everything went together smooth and should come apart good again if needed. Just clean and lube everything!

Also check your steering bearings for play while you have the whole front end apart, see how much it moves side to side and up and down in the downtube. I think mine might just need fresh grease, its tight and not loose but making squeeky noises when turning.

[jdtench]

Ok, got the front done and it's all put back together except for the seat. I got word from Cosmic Quads that the seat is finished. Just waiting on it to get here. I greased the heck out of the front when I put it back together, so hopefully it'll come apart easily if needed. I guess I buggered up the threads on the front axle, the nut wouldn't go on. I had to get out the Dremel and grind off the first three rows of threads, but finally got the nut to go back on. I took it over to my parents house to ride it around a little (sitting on the back rack) and noticed that is is slipping. I have noticed that it is jumpy when trying to ease the throttle when stopped and when I shift gears it winds a little before it feels like it catches. I'm thinking both the centrifugal boots and the disks need replacing. Anyone have experience doing this? I've scoured the forum and saw where one guy build his own tool out of a socket to take apart the clutch. I'm thinking this might have to wait a while anyways, looks pricey. I might as well replace the clutch springs while I'm at it.

Oh, I got a cig style power plug on it, actually wasn't hard it all. It works great too!

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[jdtench]

Ok, got it put back together with the seat and a new mount for my Garmin GPSMap 60csx. Took it for a short ride today and got to see how fast it is. Here's what the Garmin told me!

http://i1240.photobucket.com/albums/gg488/jdtench/IMG_0294.jpg

And, I got some final pictures of it. I know it isn't as nice looking as some of the other restores on here, but I did what I could with the limited space and $ that I had.
http://i1240.photobucket.com/albums/gg488/jdtench/IMG_0290.jpg
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[jdtench]

Closed....