My last 200x build...Hopefully

[oldskool83]

Here it is.

Check it out. I have a NOS 87 200x fork set to use, redid a 350x front rim / hub assembly. 200x +2 swinger. CNC turned carrier for 300ex axle centered, with laser cut extensions to follow the original tube angle (most guys weld this section straight and it looks funny) YZ426F front caliper with dual phenolic pistons, dual row LSR 300ex bearings to fit in the carrier and seals. My homemade design shark fin skid place since I run TRX sprocket guards from DRW. Rear rotor hub is 1985 ATC250R and so is the rotor. I had to just index the caliper to fit on the rotor in a good spot and HRE made me a caliper mount. HRE also welded it the swinger up for me. I did the rest. The sprocket guard I made.

The axle set up took me some time to figure out, however it was not bad once you put your head to it, used math & a digital caliper.
I did have HRE gusset the front of the frame where they like to break at the bottom motor mount and put in the missing right side frame gusset by foot peg. I supported rob wicks again with this foot pegs. Chain guides...well that's my last name on it and I did a run of 7 on a CNC.

Should turn out cool. Stay tuned for the slow show.

[MrConcdid]

Looks great, you have the skills to pay the bills, nice work.
MrC.

[Footy]

That should be the meanest cleanest 200X ever!

[shortline10]

Nice work Aaron !

[oldskool83]

Bought 2 85 motors...fixed up a front end until all new stainless hardware shows up. Pics to follow

[oldskool83]

Here's me Hondaline headlight guard that took 2 hours of careful heating and bending to make fit again correctly. These are 1985 triples that I wanted to throw people off with....pull the 86-87 200x style with the black upper tree since I am going to use NOS 87 forks and black boots. Lot of time, but over the last year of buying selling trading I have managed to get everything I need for no cost to me. This is the only way I will build a vintage toy anymore unless I DO NOT pay for it.

End of Day I always hand build my toys, because its all new and i come in right around where the fools are asking for clamped out broken used junk...

Thinking about going Pro-x piston on stock compression so I can run ethanol free 90 I can get locally. All my current machines are running stock motors since I'm just trail riding with a 5yo...not needing high compression or crazy nice fuel. Man stuff last long when it's stock. Accepting it for what it is is the best part!

[ATC King]

Keep it going. I feel you on the stock engine. Unless racing or trying to hang with more powerful machines in the open, there's no need beyond stock. Simple, reliable, inexpensive, there's really no downside to a stock engine for basic trail riding.

[oldskool83]

I do have a cobra header and I will make my own exhaust off some OEM muffler off some 450F or something that flows pretty nice. I don't need loud I am going over to HRE after work, should come home with the goodies to share.

[Red Rider]

Nice work! Trying to understand what is going on with your rear sprocket. It must need to be offset, to align with the front sprocket, due to using centered 300EX carrier?

[oldskool83]

Yes I am running the sprocket offset due to the front. Also there is a DRW honda sprocket guard in the mix of the dual spacers. I pulled the NOS 87 200x forks out of the OEM Honda box down from the loft last night. Here is more of the pegasi unicorn

[Red Rider]

... with laser cut extensions to follow the original tube angle (most guys weld this section straight and it looks funny)...I agree. Much more aesthetically pleasing, the way you extended yours.

[oldskool83]

DOMINOS Pizza said it best. Failure is an option....well we had a failure, we must learn from it and fix it so it does not happen again. I had ordered my new axle bolt, spacers and tank bolts from ATC-ATD on facebook. I have a bunch of Craig's stuff and its spot on. We talked a bit on my failure issue. I now have confirmation that the 85-86 350X front hub is 16mm narrower then 83-87 200x, 83-84 250r.

This is great. I had a spare 85 350x front wheel set yup and decided to use that due to the smaller bolt pattern if I ever decide to go to 10" front wheel again.

That's where my problem started I didn't realized I had. I will be making Craig drawings to solve this issue as he said I am the 3rd person who had this issue this year. Lucky the fix it easy, however lets document it and give specs back to the builder to offer a kit for the fix. He's bigger than I am. We talked a bit about me NOT coping him out of respect since I also work in a machine shop. I am not here to make money off others who put the time in. It's called Respect. I need to have 8mm extra added per side to the 200x front wheel spacers and two 8mm spacers to move the caliper over to match the rotor. Funny 1 things caused me all these issues.

I hope he will appreciate my work and dedication to fixing this issue for future people. I work too much at work to sit here and try to make money off a few parts anymore. I'm shutting the doors on the 20 years of eBay parting out, spending time with my daughter and working a boat load of overtime at work. I am not poor and free money is just too hard to make anymore these days. I'd rather take all my free parts and build something from them. Little problems happens. Fix it and move on. This could spark something greater in the future if ATC-ATD really blows up. If not I am happy to offer some quick engineering help. Just set me back maybe 2-3 weeks to see this front end ROLL, no big deal.

[oldskool83]

Spend some time checking things.

350x hub is all kinda offset all over the place.

I need to add 13.75mm to the non brake side of 200x spacer. I need to add 1.5mm to the brake side of 200x spacer. Now wheel is perfectly centered. No the 200x caliper will not mount onto the 350x hub. The offset of the rotor does not allow this to happen unless you remove rotor. 350x rotor studs will bite into the 200x fork. They need 1-1.5mm removed fro them. Still not hatefull. However due to the casting provisions of the 200x forks for the caliper mount that needs milled down. (I stopped at this point) I was not milling a set of NOS forks.

Yes I solved the problem but not going to destroy mint parts that are ever increasingly harder to find. Buy what you need, move on. I ended up giving this information onto ATD-ATC also so he has something to stand on. It's better then just telling someone NO it does not fit...because people will ask WHY does it not fit. Maybe I keep the 350X front hub in-case I run to a 350x again who knows. Honest mistake on my end. I assume 2nd gen 200x and 350x front hub were the same but nope. Honda really mucked this system up lol.

I bought a 86 200X front hub, least my front is is all period correct now. Just need to powder coat and rebuild the hub. Set myself back a few bucks and say 4 weeks...AH!!!!!!!!!!!!!!!!!!!!!!!!!

[oldskool83]

So I tried to ASK BVC trikes if they could sell my their 250R headlight kit as a DIY since I already had a white shell. At the time they were not selling white shells and I didnt know they were making a headlight kit thats crazy priced for the people who cant think or wrench.

Well I got some stupid rude comments back from them. I am not posting it since I do not want any pissing matches to happen. Well lets put it this way I wanted to sent my shell in if they wouldn't after they told me to just buy another. I tried to stress with photos I already have a white shell here why would I buy another one?! They told me keep it as a spare....

OK another company pissed Big A off...and when that happens I do do something about it now.

Here is my solution to mounting headlight on ANY ATC...and not using over priced $200 40 year old rubber straps we hope are not dry rotted. These are my prototype parts and still not finished. I will be addressing the mounting screws to look like the press in pop pins somehow, either counter bored holes or counter sunk screws.

I have these bored to work on 33mm forks, I could have this done to work on 35mm and 41mm ATC forks....this was all done in a CNC mill. See what happens when you piss me off. Same went for the chain guides. CNC mills are great. Who wants 200x ones?

[oldskool83]

Back at it.

1980 ATC200 top end parts used for manual decompression
closer to fixing rear brake pedal / master cylinder area (trx200sx atc200 trx300ex used engineering purposes)
rear shock all redone & revalved for me
New engine plugs since all the OEM ones are junk and slotted screw drivers blow

njoy until next time.

[350for350]

I was beginning to wonder where you were going to use that Engine Ice. Then I saw that it's just a kicker hold down.

[86T3]

Man, I think those NOS forks could sell for enough money for you to get a much better front end. If it were me, I'd throw those back in the box and see what I could get for them.

[oldskool83]

I could but but period correct toys are still drool cool. Who knows what this trike will really turn into. Today i finished cutting up a foot pedalto use...and there will not be any engine linkage bullshit either. I have to order some oilite bronze T-hat bushing yet. When your in no rush cool ideas just pop into one mind.

Stay tuned.

[oldskool83]

Making a real foot pedal for the 200x. This will solves one of the last issues with 1st gens. I used oilite bronze bushings as my 1st test. My next idea is uhmw. Not finished but you get the idea. It attaches to the lower foot pedal boss, not the upper rear one.

[oldskool83]

450R Master cylinder and res mount. Frames is done now. Off for color next week.

[patriot1]

Super nice. thanks for the updates.

[oldskool83]

been busy...maybe this helps someone. I feel it better to fix the machines little problems no one addresses...but hey I'm anal and work in a machine shop too.

[Footy]

nice! I have wanted to try a modern mx bike rear mater cylinder which incorporates the reservoir and mc into one piece.

[Shad Owe]

been busy...maybe this helps someone. I feel it better to fix the machines little problems no one addresses...but hey I'm anal and work in a machine shop too.

Not a fan of the rear master and link geometry. Should be lower and closer to the frame so the pedal tab isn't clocked so far into the range of motion. Unless you have a pedal stop which would be weird, it has a risk of flopping past and the pedal dropping. Time will tell.

[oldskool83]

I needed to leave room for the chain adjustment system. There is room on the upper pedal peg post to attach a return spring. The kicker and chain adjustment do not leave much room for ideas to move items. The foot petal was going to get a wire attached to frame. However on my laster I run neither the pedal wire strap or a return spring and the master cylinder returns by the spring tension in the 450R master cylinder.

I think this is the 3rd frame I have changed a pedal and master cylinder, each keeps coming up in similar locations. The 200x frame is just too small. If I wanted the pedal on the motor none of this would of been needed.

[Shad Owe]

I needed to leave room for the chain adjustment system. There is room on the upper pedal peg post to attach a return spring. The kicker and chain adjustment do not leave much room for ideas to move items. The foot petal was going to get a wire attached to frame. However on my laster I run neither the pedal wire strap or a return spring and the master cylinder returns by the spring tension in the 450R master cylinder.

I think this is the 3rd frame I have changed a pedal and master cylinder, each keeps coming up in similar locations. The 200x frame is just too small. If I wanted the pedal on the motor none of this would of been needed.

See folks. He knows what I'm saying because he actually does this stuff. Didn't take offense to a suggestion just explained his method. Exchanging ideas.

I have an aftermarket motor so I had to make a pedal too. My master is in the stock location and it works fine. If it works it works but it definitely doesn't HAVE to be that way. Just hate to see that pedal over rotate dig into the ground and turn into an ankle breaker.

[oldskool83]

I had one idea to use a lay down master like they do on scrambler 400/500's but the foot pedal would of been so small and needed a boss put on the main frame under the motor. The pedal is the last thing to do on. It's done but I want to triple check once the motor is back in, kicker rebuild etc. Some guys want to retain the full OEM-ness of these toys. I think that's great if its going to sit around. I want to use it and not keep on hoping for nice parts at 40 years old. I had about $8 in new oil-lite bronze bushings.

As long as the travel looks when it was all hooked up I only had 1/4" of pedal play. About the same as most other atvs I have here. The span looks long, however the extension adapter only added 3" It ended up being just a hair longer then banshee / warrior rear master cylinders. I had many here to choose and play with. I stuck with TRX450R since I run all that same stuff and have spare parts for my blaster using it. I am also using the same master cylinder on my TRX200sx I am converting to rear hydraulic disk brakes. I try and allow for tool / maintenance work on the machines also. I didn't just slap something on there, but the more you do something and more people involved the better product and outcome you get. This is why I like the forum better then FB group. The guys in the groups have no thinking or money to even try an idea out. Well some of the big players so but lets face it, most guys are not putting 10 grand into a 200x. Neither am I, Most of my things are build from spares laying around from parting machines out. I just want it to look like a 200x when I am done and fix a bunch of it's oddly designed worn out issues. I've learned to no take offense to anything, no need to start issues / make people mad. Just all work together and learn from each other.

[oldskool83]

Got my frame back so now by the weekend it will roll.

[oldskool83]

Bit more. I am trying to all chassis related items to clean off the work benches before I open another motor to fix 1 good one. Ordered a new LED headlight to fit the 86R shell. Next step is mount that in the shell.

[oldskool83]

BACK cut kicker gears, ordered correct shims for it and a new xr200 spring.

[oldskool83]

Finished my headlight conversion and its NOT BVC trikes headlight. I made my own & its all stainless steel. Enjoy.

[Red Rider]

It all looks very sano. Nice work!

[Footy]

Looks great! I like the way the rear brake reservoir is mounted. I need to change the reservoir mount location on the 350X as the exhaust heat has deformed it a bit.

[oldskool83]

Been rebuilding motor and odds and ends. Just pick up me new 4140 swing-arm collar from HRE last night. Needed a few more motor parts. I used a Pro-x piston kit and the head gasket was less then perfect so NOS OEM one was ordered. Pulser coil was rebuild with all new OEM parts. It was not much at all. Way cheaper then buying 40 year old worn out parts off ebay for too much money. I bought a few sets of NOS stuff just because.

All hardware is stainless now, brass washer used at the coil also. Seems 1 or two things just take for every to get here to proceed to the next step. I've built this motor basically out of a two junkers and parts puke'd in a box. The constant lets go see what what we have is a PITA.

[oldskool83]

Done with motor, next intake and let's put it in the frame. Had another home project last 5months taking up a good bit of time. Still in no rush.

[oldskool83]

Motors in, made aluminum motor spacers. Moving on. Rear sprocket and sprocket guard should be done this week. Installed a crank case breather filter last night. Almost done but still need to build a rear muffler to match my cobra header.

[oldskool83]

I did more, now to buy a good chain. I use one I had laying around for test fitting.

[oldskool83]

fixed up the worn out kicker to not be worn out.

[oldskool83]

Chains on, everything adjusted and tight. Cleaning up carb now. Sat 10 years with ethanol fuel in it...glass black nastiness inside...soaking in B12 right now.

[ATC King]

Y'all doing these top notch 200X builds put a lot of the overpriced 200Xs to shame that aren't nearly the same condition.

With yours being upgraded and modernized, it's got more value than a stocker to some people. It's crazy how that works sometimes, for vintage vehicles. It would seem they hold more value by being stock, especially original, but that's not always the case with tasteful modification.