87 200x Refresh

[jasong_10]

Well with the increasingly miserable weather and a growing honey-do list, I've decided to call the riding season until Spring. So this afternoon I started tearing down the X for what I'm calling a "refresh" as I wouldn't consider it a restomod but it's not a back to 100% OE either.

My plan is a teardown, deep clean, replace/repair what needs it, and reassemble. The engine runs strong ans doesn't smoke, and all the bearings are tight, so I'm leaving the drivetrain and suspension intact (which will make it easier to move around the garage). Grabbed a new headlight shell from shep and will get new tank shrouds from atc007 on Ebay (unless buying direct qualifies for a forum discount :D), along with new Maier fenders. Already have new wheels and tires, just need to get the front tire mounted. Got some parts stored up, some more coming at Christmas, and hopefully can buy some more with some Christmas $$.

Here's where we started:

264738

Here's where we stopped for the day:

264739

I'm cleaning everything that's going back on as it comes off.

I did come across something interesting regarding the coil, it looks like someone made a non-stock one work.

264740

It starts and runs great so they must have done it right, lol. I'm thinking about replacing it with a stock setup, I assume OE Honda is the way to go rather than an aftermarket equivalent?

[jasong_10]

Anybody know where I could get my hands on one of these? Babbitts calls it a rubber tank guard.

264756

264757

Thanks.

[Shep1970]

I did a bunch a couple yrs ago, turned out the rubber i used was crap. (now i know better) I got your pm. I looked around and found one i poured from "good" rubber 6months ago, forgot i did until i saw them. Ive gotta remake the mold to make any more someday soon, but this one is fine, others in pic are fails- "now that i know how to get the mold right" i gotta re-do it.:)
I think i still have your address, i'll stick it in the mail "usps" this wk end-
i'll stick a fail in there too so u can give it a strength test.264758

unless u find one before then.

shep

[sledcrazyinCT]

Shep makes great repops! Speaking of repops I need the rubbers that insulate the rear shock reservoir

[Shep1970]

Shep makes great repops! Speaking of repops I need the rubbers that insulate the rear shock reservoir

thanks, the rear shock reservoir rubbers, I have nos ones-well 2 of them there on the coffee table taunting me every night:D that ones a bit more complex due to the sleeve the frame part slides into. getting closer to trying, i'd just like to get it right the first time. definetly takes some thought.... kinda like puzzles i guess (brain teasers).

shep

[jasong_10]

Here's where we're at after day two.

264796
264797
264798

Got everything off that's coming off other than the wheels/tires and front plastic, painted everything that gets the epoxy paint, and wiped down the entire machine. Just have to pick up some high temp exhaust paint and spray on bedliner to do the exhaust and skid plate. Once those get painted I can start putting it back together.

[jasong_10]

Day three pics.

264982

264983

264984

Got everything but the rear hubs painted, the front skid plate looks white in the pic but it's actually pretty close to the aluminum that was OEM. I did put the top triple clamp back on because I didn't like having it off with all the weight of the front tire/brakes/etc. still on there. I'll grab some more epoxy paint at work Friday and paint the rear hubs this weekend hopefully.

How does the front wheel/tire assembly come out? It looks like the lock plate unbolts/comes off the left side, then the axle unscrews from the right side . . .

Can some one confirm or correct this?

[Shep1970]

Yes, front wheel- "loosen" don't remove the four front axle clamp nuts for now. Lefty loosy on the bolt (no power tools) do it by hand, its a steel bolt that threads into aluminum (dont strip it out). It'll either come out easy or if bolt is grooved because of old worn bearings this may be more complicated........
Go back and forth as your loosening the bolt when it starts moving. A little heat can help (near threads) lower fork if needed. Good luck.
Oh, you do not want to force the fork away from tire while loosening, it needs to come out the side your wrench is on.
sometimes better to remove forks from the tripple tree. You'll see:beer
shep

ps. mailman deliver the tank rubbers yet?

[Blmpkn]

Not trying to hijack... but shep, ill likely be in touch for some rubber stuff for my 200 build in the coming weeks/months. Whatever isn't readily found on ebay.

[Shep1970]

Not trying to hijack... but shep, ill likely be in touch for some rubber stuff for my 200 build in the coming weeks/months. Whatever isn't readily found on ebay.

ok, the wifes gonna re-list all i have plus a couple new items over the wk-end. So whenever your ready, i think i have enough "stuff" molded up to last for a while.
you can always pm me here instead of posting.

shep

[jasong_10]

Yes, front wheel- "loosen" don't remove the four front axle clamp nuts for now. Lefty loosy on the bolt (no power tools) do it by hand, its a steel bolt that threads into aluminum (dont strip it out). It'll either come out easy or if bolt is grooved because of old worn bearings this may be more complicated........
Go back and forth as your loosening the bolt when it starts moving. A little heat can help (near threads) lower fork if needed. Good luck.
Oh, you do not want to force the fork away from tire while loosening, it needs to come out the side your wrench is on.
sometimes better to remove forks from the tripple tree. You'll see:beer
shep

ps. mailman deliver the tank rubbers yet?

Okay, thanks shep, yeah I'll make sure to take my time.

I haven't got to the PO box since Thursday of last week, so I'm not sure, I should have time to check it tomorrow. You sent it to the PO box I assume?

[Shep1970]

Okay, thanks shep, yeah I'll make sure to take my time.

I haven't got to the PO box since Thursday of last week, so I'm not sure, I should have time to check it tomorrow. You sent it to the PO box I assume?

yup the PO box

[floydechoes2000]

Looks good so far! I always loved the 87 200X's. One thing I noticed is that your fork boots are discolored at the bottom, that usually means bad fork seals. If you haven't changed them yet now might be a good time.

[jasong_10]

yup the PO box

Okay, I should be able to check it tomorrow and let you know. Thanks shep.

[jasong_10]

Looks good so far! I always loved the 87 200X's. One thing I noticed is that your fork boots are discolored at the bottom, that usually means bad fork seals. If you haven't changed them yet now might be a good time.

Thanks, I'll check them the next time I get a chance to work on it.

[jasong_10]

[\QUOTE]mailman deliver the tank rubbers yet?[/QUOTE]

Got the mail today and they were in there, thanks again shep. I assume the "bad" one is the un-trimmed one? They all look pretty good to me, lol.

I know this may not even be possible but remembering reading through your old post about sand-casting a while back got me thinking. Is it even possible to make repop OE style grab bar? I would guess that it couldn't be hollow so it might be weaker, but that wouldn't matter to me. I know it's a long shot but I figured it wouldn't hurt to ask.

[Shep1970]

[\QUOTE]mailman deliver the tank rubbers yet?

Got the mail today and they were in there, thanks again shep. I assume the "bad" one is the un-trimmed one? They all look pretty good to me, lol.

I know this may not even be possible but remembering reading through your old post about sand-casting a while back got me thinking. Is it even possible to make repop OE style grab bar? I would guess that it couldn't be hollow so it might be weaker, but that wouldn't matter to me. I know it's a long shot but I figured it wouldn't hurt to ask.[/QUOTE]


I think one had a air bubble or something (all the same rubber mix though.) ya, i got lazy on trimming, most times if the mold is working good theres no real trimming to do or very little. I gotta re-do that mold after x-mas.
No on the grab bar.
stock grab bars show up on ebay now and then- but arent cheap when they do, and most are bent at this point. I haven't seen one for a while though so i'm sure at this point your not the only one searching - just use an aftermarket one.
you'll find out if u havent already that certain 86-87 200x parts are not so easy to locate these days.

How about a rubber grab bar?------kidding....
shep

[Blmpkn]

From what I read in another thread, there's a guy up here in Maine that has a knack reproducing parts for these old machines. Names Craig Burton, outfit name is adt atc or something of the sorts, can be found on Facebook. He can build you a grab bar.

[jasong_10]

I think one had a air bubble or something (all the same rubber mix though.) ya, i got lazy on trimming, most times if the mold is working good theres no real trimming to do or very little. I gotta re-do that mold after x-mas.
No on the grab bar.
stock grab bars show up on ebay now and then- but arent cheap when they do, and most are bent at this point. I haven't seen one for a while though so i'm sure at this point your not the only one searching - just use an aftermarket one.
you'll find out if u havent already that certain 86-87 200x parts are not so easy to locate these days.

How about a rubber grab bar?------kidding....
shep

No worries, they all look good to me, thank you again. Figured the grab bar would be a no-go, but I want to investigate every option as I have discovered that some 86/87 stuff is pretty hard to get ahold of, lol. I'm kicking myself for not buying the one I saw on Ebay a week after I bought the trike for $115, I thought that price was crazy at the time and figured I'd be able to pick one up for $50, boy was I wrong.

[jasong_10]

From what I read in another thread, there's a guy up here in Maine that has a knack reproducing parts for these old machines. Names Craig Burton, outfit name is adt atc or something of the sorts, can be found on Facebook. He can build you a grab bar.

I'm familiar with Craig and ADT ATC, and there is actually another person on FB that makes them as well. My hang up with them is that they both use flat stock back from the frame and then round tubing for the cross piece. They look like they're great quality but I'd really like the OE look of all round tubing. So I guess for now I'll hold out and pray that I can find an OE one, haha.

[jasong_10]

Got to tinker with it again today and finished disassembly, clean up, and paint. Didn't take the front fender off because I don't think the $$ is going to be there to replace the plastic between now and next spring and I plan on riding it next summer, so it'll have to wait until the fall of 2021.

265041

265042

265043

Even had time to put the headlight back together, shout out to shep for the headlight shell.

265044

[jasong_10]

Got some time to work in the garage tonight. Did the final mock up of the homemade grab bar section and prepped them for welding.

265369

265370

Also bagged and labeled all the hardware, as it might be a minute before I get to start reassembly. Honestly I was a little proud of myself, actually remembered what everything was/where it goes, lol.

[Dirtcrasher]

I replied in your other thread, you need support for the bolts or the tube just crushes.

For a long time I have wanted to make aluminum tubular grab bars, but I also need to get a 50 x 30 shop built before I keep buying new machines. I'll get there, I may be ready to die by the time I do, but I'll do it...

[jasong_10]

I replied in your other thread, you need support for the bolts or the tube just crushes.

For a long time I have wanted to make aluminum tubular grab bars, but I also need to get a 50 x 30 shop built before I keep buying new machines. I'll get there, I may be ready to die by the time I do, but I'll do it...

I did see your post (apologies for not acknowleding it, the last couple weeks have been crazy), and appreciate the catch. My plan is to use round stock with an OD as close as possible to the ID of what I've got so far.

I know, the aftermarket ones out there look like high quality pieces but, I really prefer a bar completely formed from round tubing versus the flat stock on each side . . .

[jasong_10]

Well, had some time to tinker tonight after the kids went to bed so I took a run at recovering the seat. Got the old cover off, all the old staples out, and the seat pan cleaned up, but after an hour of unsuccessfully trying to install new cover, I decided to give up. Once we get clear of the holidays I'll get ahold of my buddy that did the one on my R, well worth the case of Blue Light that it cost me, lol.

[atc007]

Looking great ! Just saw this. Of course you qualify for a discount , everyone here does! She's gonna be a beauty when you're done !

[jasong_10]

Looking great ! Just saw this. Of course you qualify for a discount , everyone here does! She's gonna be a beauty when you're done !

Thanks! The new fenders should be here this coming Thursday so the shrouds are the last thing I need to get, but now the Trike Fund is at $0 so I'll have to wait until I get some side work to replenish it before I pull the trigger. I saw no PMs in your sig, so should I e-mail you when I'm ready to get them?

[jasong_10]

New plastics showed up today so I couldn't resist tinkering with them. Drilling the rear fender was an adventure, made the mistake of starting at the back . . . so I've two sets of holes for the seat pan studs, lesson learned. Front fender went better and all the decals laid down pretty nice. Here's the night's work.

265900
265901
265902

[jasong_10]

Things are coming together pretty well over the last week. Got the rear tires mounted Wednesday, and was able to get my seat recovered this afternoon. So naturally I had to put the rear fender back together tonight after the girls went to bed, lol. Here's where we're at.

265930

265931

265932

My buddy did a great job with the cover, and even considering my hack drilling job, I'm really happy with it. It's not perfect, but that's not what I'm shooting for, this is going to be rider, not a show piece.

[oscarmayer]

nice work!

[jasong_10]

nice work!

Thanks, really starting get the itch to start putting it back together. Finding the time will be the hard part, lol.

[jasong_10]

Scored a taillight on Ebay last night, woo hoo!!!! The same seller listed a grab bar today . . . I want to pull the trigger in the worst way, but I'm relatively sure my wife would kill me. I've always heard it's easier to ask for forgiveness than permission but I don't dare use it two days in a row, lol. If nobody grabs it before next week that should be enough time . . .

[MrConcdid]

I think it looks great, good work.

MrC.

[jasong_10]

I think it looks great, good work.

MrC.

Thanks MrC, if it turns out half as nice as yours do I'll be very happy with it.

[jasong_10]

Well I didn't want to let that grab bar slip away so I pulled the trigger last night. It's a huge relief to get the last two pieces that could have been a nightmare to find, but it was an expensive week, lol. That's not including the bathroom I have to remodel now after my wife saw the Ebay purchase history, haha.

[wild200x]

Well I didn't want to let that grab bar slip away so I pulled the trigger last night. It's a huge relief to get the last two pieces that could have been a nightmare to find, but it was an expensive week, lol. That's not including the bathroom I have to remodel now after my wife saw the Ebay purchase history, haha.

I just read through this thread. will continue to follow. Got a very good friend with an 86. "Bathroom remodel". Bwahahahaha.

[jasong_10]

I just read through this thread. will continue to follow. Got a very good friend with an 86. "Bathroom remodel". Bwahahahaha.

Yeah, it shouldn't be too bad. She just wants the walls redone with the same kind of vinyl plank flooring that I used on the floors a couple years ago (a different color/pattern obviously).

[jasong_10]

Taillight and grab bar showed up at the end of the week. Light is in great shape and came with all the hardware, and all the bar needed was a couple coats of paint, which was last night's project.

266149

[atc007]

Just email when you're ready for shrouds. Looking great !!!!

[atc300r]

Sweet build .I picked up an 86 200x couple years ago I'm planning to make it a decent trail rider. First pic when I picked it up at Lowville .Honda266159 266160

[jasong_10]

Just email when you're ready for shrouds. Looking great !!!!

Will do, thanks.

[jasong_10]

Sweet build .I picked up an 86 200x couple years ago I'm planning to make it a decent trail rider. First pic when I picked it up at Lowville .Honda266159 266160

Thanks. Most of the stuff I'm replacing on mine is still functional (not pretty, but functional), you'd be welcome to come by and see if any of it would work for you when you get started on yours. You'll find out that the 86/87 stuff can be pretty hard to find, and really expensive when found, haha.

[jasong_10]

Decided to try the tank myself. Tried to get as much of the surface rust off as possible and scuffed up the bad spots, then hit it with three coats of self etching primer. Got it baking by the wood stove now.

266412

I'll take my front fender to work Monday and grab a can of automotive white that matches, and some clear.

[Red Rider]

Tanks looks cozy in there by the wood stove!

[jasong_10]

Tanks looks cozy in there by the wood stove!

Yeah it hasn't been above 15 degrees in the last three days, so I've been feeding that stove quite often, haha.

[jasong_10]

Thoughts on paint options . . .

Duplicolor automotive paint and clearcoat, or Valspar tractor and implement? Either one will be extremely close color-wise, I just want to go with the more durable option.

Thanks.

Well scratch that, I chickened out. Talked to the body shop in town and he said he would seal, paint, and clear it for $75-$100, I said sold, haha.

[jasong_10]

Got some time in the garage today. I think another couple hours and it'll be together minus the tank shrouds, which I still have to order. Here are some pics.

266882

266883

266884

[Shep1970]

Jason its finally coming together, looks good. I just made a "new" mold of those tank rubbers if you'd like new one's instead of one's i sent u that were poured a few months ago in over a 2-yr old slightly shrunken dried out mold....The lines/results in these are much better. Say the word and i'll send em your way. 266923

shep

[jasong_10]

Thanks, I'm very happy with it so far. The only snag was dropping the rear plastic and seat as I walked over to put it on for the first time, and of course it landed top side down scuffing the edges of the fender and the front edge of the seat cover, was not impressed . . .

Sure, how much you need for them?

[Shep1970]

Nothing, i'll get them in the mail thursday. I'm sure i have your address here somewhere.

shep

[jasong_10]

Nothing, i'll get them in the mail thursday. I'm sure i have your address here somewhere.

shep

Cool, thanks shep!

[jasong_10]

Got some time in the garage again today and made some more progress. The front end is put together, and the tires and rims are on. You'll have to excuse the hand-me-down rear tires/rims, the R got the new ones, lol. Here are the pics.

266949

266950

Probably should have asked this before assembly, but patience isn't my strong suit, haha. I put a very thin coat of grease on the front axle, good, bad, or doesn't matter?

Now that the wheels/tires are on, I can get it off the stand and sit on it to get the bars where I want them. Then I can get all the controls, levers, etc. squared away. After that it gets it's face (thanks to shep), and then the tank shrouds and decals will be the last piece of the puzzle.

What does everyone use adhesive-wise in regards to grips? I can't remember what my buddy used on the ones on the R . . .

[Shep1970]

I hear you may need a couple rear frame plugs:) I just might have those. 266963

shep

[atc300r]

Shep are those frame plugs for the back of the 86-87 200x.

[Shep1970]

Shep are those frame plugs for the back of the 86-87 200x.
yup they are.

shep

[jasong_10]

I hear you may need a couple rear frame plugs:) I just might have those. 266963

shep

You heard right, lol. I would take a pair of red ones. Just let me know how much you need for them and I'll send it your way. I'm going to have to put a "built by shep" sticker on this thing somewhere :D

[jasong_10]

Getting closer . . . got the bars where I want them, put the grips on, mounted all the controls and routed the wires/cables, and gave it it's face. Pulled the tank back off and brought it in the house in preparation for the shrouds arrival on Monday. I figure the warmer it is the better the decals will stick. Here are the pics.

266980

266981

266982

[atc300r]

Jason your 200x is looking great.Are you planning to go on the Snirt run if they have it.Also on March 20th Adirondack Speedway is having atv snow races at Stuck in the Muck event.

[jasong_10]

Jason your 200x is looking great.Are you planning to go on the Snirt run if they have it.Also on March 20th Adirondack Speedway is having atv snow races at Stuck in the Muck event.

Thanks, I'm very happy with it so far. I work every Saturday until 3 or 4 so that kind of puts the ki-bosh to weekend events like those, but honestly I'm a wuss, I do my riding on sunny 60+ degree days, lol.

[jasong_10]

Tank shrouds showed up yesterday (thanks Bill/atc007), so obviously I had to put them on the tank, sticker them, and re-mount the tank as soon as the kids went to bed, lol. Should have some pics tomorrow.

[jasong_10]

Got out to the garage this afternoon and tied up all the loose ends. Threw some fuel in it (no leaks, woo hoo!), fired it up to get the idle set and cure the exhaust paint, and took some pics.

267052

267053

267054

267018

Thanks everyone for the help and input along the way.

[atc007]

Looking great Jason, I’m gonna send you a set of fork boots bud.

[jasong_10]

Looking great Jason, I’m gonna send you a set of fork boots bud.

Thanks, I'm very happy with it. Cool, thank you!

[wonderboy]

Looks gorgeous! Nice work!

[Dirtcrasher]

Came out nice! What nerf did you use on there??

LMK if you want a headlight guard, that puppy looks to be about a 600$ headlight....

[jasong_10]

Looks gorgeous! Nice work!

Thank you, now I'm just waiting for riding weather to get here.

[jasong_10]

Came out nice! What nerf did you use on there??

LMK if you want a headlight guard, that puppy looks to be about a 600$ headlight....

Thank you. I think they were off a KFX 400? I got them used off FB Marketplace. The headlight is original and the shell is a "shep special" :D

[wild200x]

I really like that one. Looks amazing.

[jasong_10]

I really like that one. Looks amazing.

Thanks, I'm pleased with how it turned out.

[jasong_10]

atc007 hooked me up with some fork boots, thanks Bill!

267131

Just have to make some time to drop the front end out and put them on before riding weather gets here.

[jasong_10]

Well went to put the fork boots on today and took a couple steps backward . . .

Broke one of the right hand side lower triple clamp bolts off trying to remove it. Had about a 1/2 inch exposed on the back side so I figured it would be the easiest to bring it out the back side. Neither double nutting it or vise grips worked (sprayed it with PB blaster right after it broke), so I recruited my father in law and his torches. Well it came out but it split the triple clamp on it's way out :(

So now my father in law is going to take it to a shop that can weld aluminum and get it repaired.

[Dirtcrasher]

I'll add a picture of how I made my nerfs fit.

I chopped off those front aluminum flats and made a support mount that uses the front motor mounts and slides thru the aluminum, much stronger that way...

[El Camexican]

Well went to put the fork boots on today and took a couple steps backward . . .

Broke one of the right hand side lower triple clamp bolts off trying to remove it. Had about a 1/2 inch exposed on the back side so I figured it would be the easiest to bring it out the back side. Neither double nutting it or vise grips worked (sprayed it with PB blaster right after it broke), so I recruited my father in law and his torches. Well it came out but it split the triple clamp on it's way out :(

So now my father in law is going to take it to a shop that can weld aluminum and get it repaired.

Did you use a stainless steel bolt by any chance?

[jasong_10]

Did you use a stainless steel bolt by any chance?

I don't think so, pretty sure it's the OE Honda bolt . . .

[Shep1970]

Looks nice jason, you got one of the last headlight shells..... The shell mold decided that it was done....it split in two where it wasn't supposed to last night. So after i'd say 50ish shells it did an ok job. Swinehart (rip) told me in the beginning of this hobby that shelf life takes its tole on molds and that each part made in that mold takes a little life out of it. I was hoping for atleast a couple more batches but.........
Ya its not been a good day. Maybe i'll bury the mold outback in a shallow grave.....:( :D

shep

[jasong_10]

Looks nice jason, you got one of the last headlight shells..... The shell mold decided that it was done....it split in two where it wasn't supposed to last night. So after i'd say 50ish shells it did an ok job. Swinehart (rip) told me in the beginning of this hobby that shelf life takes its tole on molds and that each part made in that mold takes a little life out of it. I was hoping for atleast a couple more batches but.........
Ya its not been a good day. Maybe i'll bury the mold outback in a shallow grave.....:( :D

shep

A moment of silence . . .

. . .

. . .

Now if we could only hear Taps playing :)

Really appreciate the shell and other smaller pieces, thank you.

[jasong_10]

Well thanks to oldskool83/Aaron, crisis averted. He hooked me up with a steering stem to replace my damaged original. Pretty sure the machine shop hasn't even looked at mine yet to see if they can repair it so I'll probably just go pick it up some time this coming week. All that's left to put back on is the front tire/wheel/hub assembly. Here's where we're at, shout out to oldskool83 for the stem and atc007/Bill for the new fork boots!

267282

[jasong_10]

Well buttoned the rest of it up today, now just waiting for good riding weather to get here.

267294

[jasong_10]

I hear you may need a couple rear frame plugs:) I just might have those. 266963

shep

Could you send me a pair when you have time? I'll send you something for them and/or the shipping.

[jasong_10]

Got it out tonight for it's maiden voyage and took a short ride. Different tread style rear tires feel like they make a difference, easier to start the slide and much more stable in the slide. I was considering some spacers bug I think I might leave it as is.

[Red Rider]

Nothing like that first ride, and seeing & feeling all your hard work come to fruition! Congrats.

[Shep1970]

Could you send me a pair when you have time? I'll send you something for them and/or the shipping.
If u would give/send me like $10 bucks for a set- that'll cover shipping etc. I will send them out tuesday at the latest.... thnx

shep

[jasong_10]

Nothing like that first ride, and seeing & feeling all your hard work come to fruition! Congrats.

Thanks, now I just have to mix some gas to get the R out :)

[jasong_10]

If u would give/send me like $10 bucks for a set- that'll cover shipping etc. I will send them out tuesday at the latest.... thnx

shep

Done, thanks a bunch shep.