Yet another 200x rebuild thread. DONE!

[dansvan]

Hello all. Here's a build up on the Auto 200x project. I've been collecting parts for it for some time now. It will be my wife Carries, and seeing as it came with no engine we'll be putting an auto clutched 200 in it. The engine will sport a high compression piston, XR200 cam, ported head, 200x carb, and a DG exhaust.

Here's a few pics of the 200X in the condition I got it.

http://www.supermotors.net/getfile/599260/fullsize/p1010351.jpg

http://www.supermotors.net/getfile/599261/fullsize/p1010354.jpg

http://www.supermotors.net/getfile/599262/fullsize/p1010356.jpg

http://www.supermotors.net/getfile/599264/fullsize/p1010360.jpg

And here's a few of it's current state.

http://www.supermotors.net/getfile/599265/fullsize/p1010711.jpg

http://www.supermotors.net/getfile/599267/fullsize/p1010710.jpg

http://www.supermotors.net/getfile/599268/fullsize/p1010709.jpg

I'll post more as the rebuild goes along.

[69HemiGTX]

Lookin' good! :beer I'll be building an Auto-X for my wife, too, but her's will have a stock engine. It will still be a fun play-around trike, though.

[84honda200s]

looking great man. i built me a ragg auto x but its got a beefed up motor too. i think you will wanna ride it more than she will. they are good fun machines.


looking great man !! looks great so far.

[Nick_R_23]

Looks great!! Hurry and get that thing finished so you can bring it out here and get 'er DIRTY!!! :beer Did you have your frame PC'ed or just painted?

Just out of curiousity,, you wouldnt happen to have a spare seat pan in the pile of 250r parts you said you picked up that youd be willing to sell?? Im on the lookout for one!! :naughty:

-Nick :TrikesOwn

[dansvan]

Thanks guys. I'm sure it will get plenty dirty. Not powder coated, but epoxy paint. No extra seat pan. Gotta keep the extra one for the next build.

Which wheel hubs will give you an extra inch per side? 400ex? I forget.

[69HemiGTX]

Which wheel hubs will give you an extra inch per side? 400ex? I forget.

Yup. 250X/300EX/400EX hubs are all the same. I've got two pairs of brand-new hubs for my 200Xs. :w00t:

[Bryan Raffa]

Nice Dansvan.. I need some paint for mine...

[wad]

Looking good dude,
Keep the pics coming.

[dansvan]

Here's some of the front forks installed. I spent some time polishing them up.

http://www.supermotors.net/getfile/600734/fullsize/p1010714.jpg

http://www.supermotors.net/getfile/600735/fullsize/p1010715.jpg

New used fender. Pre-restore/buff job.
http://www.supermotors.net/getfile/600736/fullsize/p1010717.jpg

http://www.supermotors.net/getfile/600737/fullsize/p1010718.jpg

[saleen_n_around]

More details on the paint.......paint code for mixing or rattle can brand....? Anything?

[dansvan]

The paint is an experiment. This is a budget build and I did not want to go the powdercoat route on this one. I wanted a fuel proof paint. When I was checking around earlier I couldn't get JP1 mailed up here due to 9/11. (since worked around that) So I looked locally and found this. Lustre-coat by Top Flite. It's built for models running nitro. I figured if it could handle that I should be ok. It comes in lots of colors. I'm using their primer, color, and clear. Their aluminum color looks good too. As for how it will hold up? Remains to be seen. It seems pretty tough thus far. I've dropped a few tools and had a few close call with no damage.

http://www.supermotors.net/getfile/600738/fullsize/p1010720.jpg

[Eric250R]

Very nice job on those forks, looks really good.

[dansvan]

It's a roller!

http://www.supermotors.net/getfile/601228/fullsize/p1010742.jpg

http://www.supermotors.net/getfile/601231/fullsize/p1010740.jpg

http://www.supermotors.net/getfile/601232/fullsize/p1010738.jpg

[hondaracer11]

will a 83 atc200 motor fit into a 83200x frame iv been wanting to do the same thing but wasnt sure if you had to mod anything at all

[edog]

will a 83 atc200 motor fit into a 83200x frame iv been wanting to do the same thing but wasnt sure if you had to mod anything at all

Yes........

[Nick_R_23]

will a 83 atc200 motor fit into a 83200x frame iv been wanting to do the same thing but wasnt sure if you had to mod anything at all

You can put one in, but you will have to make your own front and top motor mounts. And you will also have to make your own rear brake lever, and sometimes make a custom shifter. Other then that, it will drop right in.

-Nick :TrikesOwn

[wad]

http://www.supermotors.net/getfile/601232/fullsize/p1010738.jpg
Your forks are looking very very good what work have you done to them?

[dansvan]

Thanks. Here's my ammature process. I clamped my 3/8 drill in my vice. I installed a brass fine grade wheel in to the drill. I used it to remove all the factory clear coat. This also removed alot of the imperfections. I used a flapper wheel with 220 grit paper to remove some of the deep rock rash. I then mounted a 6 inch buffing wheel in my bench grinder I paid 6 bucks each for two wheels. I used #5 polish (fine, 4 bucks) and went to town. I used the other wheel with no polish to remove the residue and add more shine. I then used products from metal wax.com for a final shine. I'm pleased with the results. I've used this process on alot of the pieces. It's not show quality, I didn't get into the really tiny crevices, but it looks pretty good.

[thefox]

You can put one in, but you will have to make your own front and top motor mounts. And you will also have to make your own rear brake lever, and sometimes make a custom shifter. Other then that, it will drop right in.

-Nick :TrikesOwn

I thought 200x mounts and shifter worked?

[brapp]

hey try usign jsut a rag and put the fork tube int he vice with rag wreaped around it and use another rag in a back and forth motion with soem polish on it to get the tight areas

[Nick_R_23]

I thought 200x mounts and shifter worked?

My bad, I was thinking of another project at the time...dont listen to me. :lol: But I know for sure that you have to make a rear brake lever, and I think you had to do something to the shifter to make it clear (put a spacer in the footpeg or something).

-Nick :TrikesOwn

[Bryan Raffa]

looking sweet... I'm almost too that point..your making me wish I polished my forks...

[scooterroo]

the x is looking nice, but i still dont get why people get rid of the manny tranny for an auto...complete loss of power in my opinion.

[dansvan]

Mine came motorless. My wife will be the primary rider. She does not want a clutch. Good enough?

[dansvan]

Here's a couple of pics. 86 250r headlight and fender, 200x headlight guard. Mock up stage.
http://www.supermotors.net/getfile/602942/fullsize/p1010745.jpg

http://www.supermotors.net/getfile/602941/fullsize/p1010746.jpg

http://www.supermotors.net/getfile/602940/fullsize/p1010747.jpg

DG exhaust mocked up. Going to make a turndown for this muffler.
http://www.supermotors.net/getfile/602939/fullsize/p1010748.jpg

200s donor motor.
http://www.supermotors.net/getfile/602938/fullsize/p1010749.jpg

High compression piston next to stocker. Note deep vlave reliefs.
http://www.supermotors.net/getfile/602935/fullsize/p1010752.jpg

200s intake next to 200x
http://www.supermotors.net/getfile/602934/fullsize/p1010753.jpg

200x head mildly ported next to 200s
http://www.supermotors.net/getfile/602933/fullsize/p1010754.jpg

Mess. Off to machine shop.
http://www.supermotors.net/getfile/602932/fullsize/p1010755.jpg

[200m]

looks awesome keep up the good work!

[SWIGIN]

i like the polished forks

[SWIGIN]

the x is looking nice, but i still dont get why people get rid of the manny tranny for an auto...complete loss of power in my opinion.



most 200x motors are trashed and the kickers suck

its a great thing for those who dont want a clutch

[dansvan]

New headlight and fender on.
http://www.supermotors.net/getfile/604441/fullsize/p1010777.jpg

http://www.supermotors.net/getfile/604442/fullsize/p1010775.jpg

http://www.supermotors.net/getfile/604446/fullsize/p1010774.jpg

[dansvan]

Here's a couple more pics. Welded a turn down on the muffler. Heard these DG pipes are pretty loud.

http://www.supermotors.net/getfile/606735/fullsize/p1010800.jpg

http://www.supermotors.net/getfile/606736/fullsize/p1010797.jpg

Finished putting the clear on the tank and installed it for pics. Also got the new fork boots on.

http://www.supermotors.net/getfile/606737/fullsize/p1010801.jpg

http://www.supermotors.net/getfile/606738/fullsize/p1010803.jpg

http://www.supermotors.net/getfile/606739/fullsize/p1010805.jpg

New engine pieces. ADB bored cylinder, Wiesco 10.25/1 piston, new valves, adj. cam timing gear, chain, tensioners, and valve guides. Broke a guide installing it so I'm waiting on another one.

http://www.supermotors.net/getfile/606740/fullsize/p1010789.jpg

[SeaBass8]

Front end looks really good. Kinda gives it an updated look.

I wouldn't mind doing one like that someday.

[chris200x]

So you fabbed up that endcap yourself? feel like making another one? I need something to quiet down my cobra exhaust.

Your project is coming along nicely. All these rebuild threads are making me want to get another project! lol

[dansvan]

So you fabbed up that endcap yourself? feel like making another one? I need something to quiet down my cobra exhaust.

Your project is coming along nicely. All these rebuild threads are making me want to get another project! lol


On the end cap I purchased a short 2 inch piece of muffler pipe from an auto parts store. I cut it at an angle and welded it right to the removable core on the DG pipe. I haven't heard this pipe yet, but I've been told it's loud. maybe directing it down will lower the db's some. I guess you could install a large washer with a smaller hole than the core outlet as well.

[Louis Mielke]

I'm liking the looks of this. I spent the good part of a weekend on ATCTim's auto X and honestly its one of the best bikes I've ridden for just plunkin around on. You'll love yours with the performance mods you're doing!

[3Wheelers4Life]

wow, this is looking really good. like everyone else said, i like the polished forks. i hope mine turns out this good. keep up the good work.

EDIT: I know you probably dont want to stand the bike on the grab bar, because you got it looking real nice. but if you were to, would the dg exhaust hit the ground while using a STOCK grab bar? would it still hit it if you did not have the turn down and using a STOCK grab bar? thanks.

[dansvan]

I tilted it back and the first thing that hit was the muffler turn down. Looks like without the turndown the bar and muffler would hit about the same time. I think my grab bar may be bent upwards slightly, but not alot. I may build a custom one or go with a PRM. I just dont like the look of the straight back ones.

[3Wheelers4Life]

ok, thanks. dont want to hijack your thread, but i was looking to get a dg exhaust, and i like the stock grab bar better. i was just worried if when i pull wheelies, or set the bike on the grab bar, it would hit the ground. thanks.

[dansvan]

Here's some more.

Degreeing cam.
http://www.supermotors.net/getfile/608263/fullsize/p1010808.jpg

Engine installed. Still lots to do.
http://www.supermotors.net/getfile/608262/fullsize/p1010809.jpg

http://www.supermotors.net/getfile/608264/fullsize/p1010813.jpg

[edog]

Looking good!!!!!!

[Havoxx]

Nice bike, be careful with that paint though, if you use it on stuff other than plastic/wood it may not adhere properly and break, it's made for plastic/balsa models, I know normal paint won't adhere to plastic, so it might be the same for that :D.

What's that your doing on the engine though? Gotta time the hondas manually? My suzuki has marks for it lol.

[84honda200s]

what did you have it bored to ? how much is it ported ? looks pretty good man. i love the forks too. i have a modified 200s motor in my 200x and its a freaking blast. what kinda gearing you going to run ?








What's that your doing on the engine though? Gotta time the hondas manually? My suzuki has marks for it lol.



honda has marks as well. unless he has a lighten flywheel. it doesnt look like it though. i would say its probably easier to see that big ars wheel than the tiny marks threw a tiny hole. i know if i had one of the bad boys id be using it. thats for sure.

[thefox]

It's looking great! I like how you took the time to clean and paint the engine black, an auto-X in disguise. Most just jam the auto engine in without painting it; I think it looks much better to have a black engine in a 200x frame.

Did you figure out how to get that adjustable cam gear setup? Maybe we can talk you into posting a how-to once it is set, for future reference. I have though about trying the gear but don’t know how to get it set properly and if it's as much of a pain as trying to set points I could really use a how-to guide!

[dansvan]

Thanks for the replies guys.

Havoxx- Not worried about the paint. Only used it on the tank, frame and swingarm. No plastic. We'll see.

I was checking the cam install because in a previous life the flywheel was loose on the crank and the key was chewed up. I replaced the woodruff key and wanted to verify the actual crank to cam relationship. Found the marks on the flywheel were off by 2 degrees. I also used it to see how much the extra positions on the adjustable cam gear gave me. I decided to install it straight up. Have to keep telling myself this is the wifes machine. After riding it I'll see what the power band feels like and go from there.


84Honda200s - Bored the first oversize over. It's mildly ported. I got a 200x head with a minor casting flash clean-up. I opened the neck under the valves slightly and blended the valve guides in. Worked on the short side turn on the intake and just smoothed everything out. I didn't open the actual size of the inlet or outlet much at all. I used the 200s valve cover for the compression release. Had to add a spot of hardweld to the actuator to get it to touch the rocker arm. Guessing the cam I'm using has a different base circle or minor maching differences on the head. Gearing = 11/40 That gives me a 3.63 final. Stock 200x was 12/40 or 3.33 final. If I need more low end I'll run a 43 tooth rear for a 3.90 final. Tried to pick a middle ground.

thefox- I agree. Black engines look good in the 200x. I stood there staring at the cast aluminum colored paint but couldn't get myself to do it. Glad it's black. I'll try a how to on the cam gear in awhile.

[dansvan]

I have a question though. I purchased a stock 200x carb. on ebay. I also bought what was sold as a 200x intake for a 85. The carb. looks and measures as a stock 200x carb should. But the intake where the carb. bolts on is alot bigger. The oring on the carb may seal against it but it will be close. The intake tapers down to match the head perfectly. I think I got an XR intake? The opening measures close to 30mm. The intake for the 200s fits the carb perfectly. (but not the chassis) I think I'm going to order one of the imported 27mm carbs off ebay and run it with my larger intake. Does anyone know if they accept stock jets?

[dansvan]

Well here it is. I put the ebay 27mm carb. on. Machine runs great so far. Not too loud either. Need to get a PRM rear skidplate and it will be done. Here's a bunch of pics.


http://www.supermotors.net/getfile/618322/fullsize/p1010137.jpg

http://www.supermotors.net/getfile/618323/fullsize/p1010136.jpg

http://www.supermotors.net/getfile/618324/fullsize/p1010135.jpg

http://www.supermotors.net/getfile/618325/fullsize/p1010134.jpg

http://www.supermotors.net/getfile/618326/fullsize/p1010133.jpg

http://www.supermotors.net/getfile/618327/fullsize/p1010132.jpg

http://www.supermotors.net/getfile/618329/fullsize/p1010130.jpg

http://www.supermotors.net/getfile/618332/fullsize/p1010126.jpg

http://www.supermotors.net/getfile/618333/fullsize/p1010121.jpg

http://www.supermotors.net/getfile/618331/fullsize/p1010128.jpg

http://www.supermotors.net/getfile/618330/fullsize/p1010129.jpg


Oh well. You get the idea. One more set of pics left. Hopefully the young lady will have a large smile on her face.

[3Wheelers4Life]

wow, looks great. it came a long way. i hope mine turns out that good. nice job. i like the 250r headlight.

[ebecme01]

is that trun down on the muffler an accessory? is there a spark arrestor that makes it legal for state parks?

[dansvan]

I made it myself. No arrestor. You could probably weld a screen over the inlet side of the turn down.