Reaming 33mm to 35mm

[Vendguy]

Has anyone ever tried to ream their 200x triple trees from 33mm to 35mm to fit 350x forks...I know we can switch triple trees...im just curious

[6spdls1z28]

Has anyone ever tried to ream their 200x triple trees from 33mm to 35mm to fit 350x forks...I know we can switch triple trees...im just curious

It’s going to change the rake of the 200x. The axle is in the front on the 350x forks and on the back on the 200x forks. Seen them on a 200x they look weird.


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[Vendguy]

It’s going to change the rake of the 200x. The axle is in the front on the 350x forks and on the back on the 200x forks. Seen them on a 200x they look weird.


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I have done the triple tree and fork swap before I like.the look but that's not what I'm asking....I'm asking instead of swapping triple trees from a 350x can I just ream the holes from 33mm to 35mm

[6spdls1z28]

I have done the triple tree and fork swap before I like.the look but that's not what I'm asking....I'm asking instead of swapping triple trees from a 350x can I just ream the holes from 33mm to 35mm

I’m sure you can. Will they crack after a while from being too thin with hard riding? Maybe. Have a machine shop bore them out


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[BOB MARLIN]

I'm not sure what you are referring to when you say "Ream" the holes out. You won't be successful using a reamer to remove .080 of material. Reamers are for finish sizing the hole, taking out minimum material, they do not cut like a drill. You will need to set them up in a milling machine and use a boring bar to size the hole. Does that answer your question ?.

[Footy]

If you were to machine the 33mm triple clamps to 35mm it would most likely create issues with the triple clamp bolt hole threads.
And as was mentioned above this could lead to the triple clamps breaking due to thinning the material.
If you need stronger forks just buy better springs and use a heavier weight fork oil.

[oldskool83]

No it wont. I've don't this 5 times. The triples were the same casting from 200x and 2nd gen 250r. They both were just machined to different sizes. Not a big deal. All these 200x's were done the same way. Milled to 35mm from 33mm....that .039 per side. not a big deal.

Both of these machines had OEM 200x triples bored. 1st set of bare triples shows no issues at 35mm, 2nd set is 33mm...you guys are moaning over nothing. I work in a freaking machine shop!

[Dirtcrasher]

IDK what year your 200X is, I only have the 86/87 models. Hands down, the best improvement I've ever made on the 2nd gen 200X was to run 85/86 350X forks and triple clamps on there. No boring necessary, it all bolts on. If you have the first gen 200X, you will need to chop off the stock steering stop on your frames neck and weld on some stops for the 350X (easy stuff, especially when compared to boring/reaming). The steering stem may need a washer (either 1st or 2nd generation 200X) for the height to be correct but it should be fairly easy to figure out, I usually stack up the old inner/outer races and balls, measure it an match it, because bearing kits have "0" instructions. I have a Bridgeport mill, and boring clamps is a PITA IMO. I made a front end for an ATC70 with some random forks, and that was failry easy to bore because I used 3/4" thick aluminum plate and I could keep everything in place on my mill as I did each operation; even steel tube can be used and welded to plate stock as they did with many early year unsuspended fron ends. You can pick up a set of 85 350X fork clamps for roughly125$ or so. Here's an super nice set for an 86 350X, with the black top clamp for 166$ shipped - Rather than posting a massive URL, this is the auction# - 13484579198 - Norcalpartsdepot always has super nice parts, I may just buy those if you don't. I apologize that the picture I'm attaching is from the rear, but this is my 87 flat track 200X with 85 350X triple clamps and forks; I powder coated the clamps in white. It was bolt on, but don't forget that you will now need a very expensive front dual piston caliper that we don't see for under 250$. Another option, may be the 83/84 250R fork clamps and or forks, they are also 35mm, and they use a common single piston front caliper; oldskool has far more experience with the 83/84 250R front end and/or all of that model machine than I do, he would know the steering stops and if rake is built into the clamps, how it fits, etc; just don't take him the wrong way and get him worked up 😁 All I can assure you of, is that the 350X forks are a "must do" for me on every 200X I own, they are stiffer, I can buy new Honda fork boots, they are slightly taller, more suspension travel, and it turns on a dime with a 350X front end installed...