1984 XR250R. The madness continues:-)

[FastDoc]

I bought the 250R :P . It only cost me $50 more than what I sold the 125 for! So net cost $200. I'm a happy miser! :D Finally some salve for my broken heart from selling The Dirt Rat :cry: .

It runs great. Starts right up. GREAT power. Smooth and torquey. Shifts stops and idles smooth. The suspension is great, and no fork seal leaks. Tires are like new. :wink:

It has a couple oil leaks. One from a valve cover O-ring one from the oil filter O-ring. The exhaust has a couple of holes. Sounds great but I'll likely swap that out for a good used stock one. Needs a speedometer cable, and a front brake lever. The cables could use some lube but other than that its good to go!

http://img.photobucket.com/albums/v25/maule/7-37.jpg

http://img.photobucket.com/albums/v25/maule/6-42.jpg

http://img.photobucket.com/albums/v25/maule/5-47.jpg

http://img.photobucket.com/albums/v25/maule/4-60.jpg

http://img.photobucket.com/albums/v25/maule/3-73.jpg

http://img.photobucket.com/albums/v25/maule/2-84.jpg

http://img.photobucket.com/albums/v25/maule/8-26.jpg

[MICRider]

Grats! I like it, cool looking bike! And two bikes in a row with red seats? Did Honda use red vinyl or are they aftermarket covers? I think you going to have a lot of fun with that bike, plus it's pretty darn hard to beat the price! :D

[FastDoc]

Believe me it runs and rides better than it looks :roll: .

It has a replacement seat cover. The fit's not perfect but the material is good and the seat is comfortable.

Does anyone know off hand what range of years I can get a muffler from?

[SpudRider]

Congratulations, Doc! I look forward to following your project. :D

Spud :)

[MICRider]

Does anyone know off hand what range of years I can get a muffler from?

I'll bet that W&G will be able to help you on that question, he seems very well versed on the XR's :)

[FastDoc]

I'll bet that W&G will be able to help you on that question, he seems very well versed on the XR's

Yup.

I'm counting on that. :wink:

[Weldangrind]

To be honest, I'm not sure about which years would interchange. It almost looks like the stainless header from my '96 would be a bolt-on. If you remove the side cover and take some more pics and measurements, I'll compare it with mine.

How bad are the holes? Could they be repaired?

Great looking bike! Are you gonna hang onto this one? Planning on dual sporting it?

[FastDoc]

The holes are not bad. Even with them it sounds fine. I was thinking some JB Weld or epoxy putty, a file and some BBQ paint would work. I don't know. I see decent mufflers on eBay for $30 but not quite the same year.

I'll pick the bike up today and take pics soon.

I think I'm gonna like this bike. :P

[FastDoc]

I think 1990 was the time of the next wave of subtle changes after 1984. Then 1996, IIRC.

[FastDoc]

Took it for a test ride.

This bike is wonderful, it may make me forget how much I miss The Dirt Rat :P .

It runs great, pulls hard, the suspension seems immune to bottoming out, the brakes are good, and the ride is smooth and the seat is comfortable.

It pulled up The Hill Of Doom in second with the rear wheel spinning the whole way but under control. It was the easiest HOD ascent I've ever had!

I changed the oil and replaced the plug. The one in there was old but no oil or carbon, just a light chocolate color. :P

One of the oil leaks appears to have been the oil filter cover O-ring which I replaced. The other seems to be coming from the rocker arm retaining bolt on the valve cover.

This RFVC engine has very complicated valve gear and I don't know how to go about fixing this leak will have to ask Andy.

I'll post pics when I can but I gotta run now. :P

Just wanted to share the good news about the DR2! :P

[Weldangrind]

Gotta love old Hondas. :D

Can Andy stitch up the muffler for you? If you can get it clean enough, he should be able to weld an' grind.

[FastDoc]

Andy I dont think welds, but Ron does. He's on vacation in California now though. No worries, no rush.

Can it be welded? I'd think the surrounding metal would be pretty thin also... Maybe soldered or brazed?

Can JB Weld take the heat? I can try that in the meantime.

I identified the oil leak. It's coming from the rocker shaft bolt(s). To remove it and replace the sealing washer would involve removing the valve cover and rocker arm assemblies :x . I may try to back it out a few turns, wrap it with Teflon tape or cover it in Permatex and tighten it up to see if I get lucky.

Today I will also service the air filter and chain.

Then I'll go for a ride. :D

This is PRIME riding season in my area. The cooler temps and some moisture keep the dust down and the trails are in better shape locally.

I'm heading to the Cascade Mountains tomorrow with Roger and Andy. The three of us will al be on KLX's. :P

[SpudRider]

Have fun, be safe, and please post a ride report with lots of photos, Doc! :D

Spud :)

[FastDoc]

Well the leaks are fixed. I was able to slightly tighten the rocker bolts and that's all it took. :P

I ground away the rotted portions of muffler. Not much good metal left!

I attempted a repair with some exhaust repair putty and some pieces of metal from a cat food can of all things. I have a feeling I'm gonna need a muffler. :wink:

[SpudRider]

Well the leaks are fixed. I was able to slightly tighten the rocker bolts and that's all it took. :P

I ground away the rotted portions of muffler. Not much good metal left!

I attempted a repair with some exhaust repair putty and some pieces of metal from a cat food can of all things. I have a feeling I'm gonna need a muffler. :wink:
It's too bad the cat food can repair didn't work. :? I bet the cat muffler would purr meowwwwwwwwwwwww! :P

Spud :)

[Weldangrind]

Rusty old thin steel doesn't cooperate well with a MIG, but a decent TIG welder might be able to patch it. In the case of my XL, I just chopped off the offending section and started again. I bought some exhaust tubing that was the correct diameter and started welding.

[Weldangrind]

BTW, I wouldn't be surprised to learn that a similar year XR200R muffler would be a bolt-on, if that helps to expand your search criteria.

[FastDoc]

Well the leaks are fixed. I was able to slightly tighten the rocker bolts and that's all it took. :P

I ground away the rotted portions of muffler. Not much good metal left!

I attempted a repair with some exhaust repair putty and some pieces of metal from a cat food can of all things. I have a feeling I'm gonna need a muffler. :wink:
It's too bad the cat food can repair didn't work. :? I bet the cat muffler would purr meowwwwwwwwwwwww! :P

Spud :)

I don't know, it may work! It hardened hard as a rock. I'll sand it smooth(ish) and paint it and run it till it breaks :P

Meow 8)

[FastDoc]

The bike is purring now. :wink:

[SpudRider]

The bike is purring now. :wink:
That's great! :D It's also very fitting. ;)

Perhaps we can now consider you a "catalytic converter." :roll:

Spud :lol:

[FastDoc]

Very 'pun-ny' Brother Spud!

[FastDoc]

I patched and painted the muffler. It looks and sounds great. No pic though...

Here's some pics of the bike where I'm at now:

http://img.photobucket.com/albums/v25/maule/DSC07716.jpg

http://img.photobucket.com/albums/v25/maule/DSC07715.jpg

Dual exhaust and dual carbs, single cylinder. Honda...

http://img.photobucket.com/albums/v25/maule/DSC07714.jpg

http://img.photobucket.com/albums/v25/maule/DSC07713.jpg

New CST rubber. :P

http://img.photobucket.com/albums/v25/maule/DSC07711.jpg

http://img.photobucket.com/albums/v25/maule/DSC07710.jpg

http://img.photobucket.com/albums/v25/maule/DSC07709.jpg

http://img.photobucket.com/albums/v25/maule/DSC07707.jpg

This is all fixed now and the newly painted muffler looks great. :P

http://img.photobucket.com/albums/v25/maule/DSC07706.jpg

http://img.photobucket.com/albums/v25/maule/DSC07705.jpg

http://img.photobucket.com/albums/v25/maule/DSC07704.jpg

Strong brakes. 1,000% better than The Dirt Rat's.

http://img.photobucket.com/albums/v25/maule/DSC07703.jpg

Remote adjustable Pro-Link suspension.

http://img.photobucket.com/albums/v25/maule/DSC07702.jpg

Dual carbs.

http://img.photobucket.com/albums/v25/maule/DSC07701.jpg

This is where oil was leaking from but thank God it was an easy fix.

[FastDoc]

I should take some 'After' pics now that's its all cleaned up...

[Weldangrind]

Regarding your brake comment, I found a donor on eBay that provided the same front end that you have. It fell into place on Son of Weldangrind's '83 XR200R; a totally worthwhile upgrade.

[FastDoc]

I think the brakes and the UniTrack suspension are the best improvement of the XR history of upgrades. I would have upgraded The Dirt Rat's front end had I kept it.

The Dirt Rat 2, or R2 as I call it is a worthy successor to the original Dirt Rat. More power, suspension and brakes with the same smooth ride and easy demeanor as the original. I kinda miss the electric start but the 250R starts pretty easily and has automatic compression release which helps.

Plus the absense of a electric starter and battery keeps the weight down some.

[Weldangrind]

I have yet to enable the electric start on Son of Weldangrind's XR200R, but I will. It feels like the kicker is going to break, because there's no compression release.

That little bike with a pushrod 230 really hauls!

[SpudRider]

I never heard of a single cylinder engine with dual carburetors. :) Do you need to synchronize the carburetors? My guess is you don't. :?

Spud :)

[Weldangrind]

That was Honda's approach in '84 and '85, with both the XR200R and the XR250R (along with larger models). With the new four valve head, they chose to keep the two exhaust ports separate, and that style carried through to modern bikes (like Spud's XR-L). I believe that the dual carb arrangement only lasted two years, after which they created a manifold that would allow one carb to feed two intake ports.

Yes, the carbs need to be synchronized, but it's not usually critical. If it was me (and I had synchronization trouble), I'd swap to the later model manifold and one Mikuni.

[FastDoc]

They work like a two barrel carb on a car.

The left carb is the primary and is the only one working at low power settings. It's the only one with an enricher.

At larger throttle openings the right carb kicks in via a linkage for more mixture flow/power.

The idea is a higher mixture velocity at low power which increases tractability and torque down low. This is a priority for an XR. Then to get max power at higher RPM's the secondary kicks in.

It works well but IMHO is needlesly complex. I suspect this is why Honda did away with it after only two years.

I am fortunate my bikes carburation is currently excellent and I have no intention of messing with it in any way! :wink:

[Weldangrind]

I had no idea that there was a progressive transition between the two carbs! I knew about the pumper on one of 'em, but I thought they pulled at the same rate. Thanks for that detail!

[FastDoc]

It's a cool but complex arrangement. 8)

I got home from work early enough to run The Dirt Rat 2. I think I'm gonna like this bike. It appears my exhaust repair is solid. :D

I found a good deal on some new reproduction plastic. I ordered a can of correct Honda Flash Red paint for the frame, and a new blue (the correct color) seat cover. I already have some black semigloss engine paint, and silver wheel/rim paint to use on the swingarm. Add in some new decals, and an hour or two sanding and polishing the tank and this bike should look OK. :P

I know, waste of time and money, but it makes me happy and it's harmless... :wink:

[SpudRider]

They work like a two barrel carb on a car.

The left carb is the primary and is the only one working at low power settings. It's the only one with an enricher.

At larger throttle openings the right carb kicks in via a linkage for more mixture flow/power.

The idea is a higher mixture velocity at low power which increases tractability and torque down low. This is a priority for an XR. Then to get max power at higher RPM's the secondary kicks in.

It works well but IMHO is needlesly complex. I suspect this is why Honda did away with it after only two years.

I am fortunate my bikes carburation is currently excellent and I have no intention of messing with it in any way! :wink:
That's fascinating! Thanks for the explanation, Doc. :)

Spud :)

[Weldangrind]

It's a cool but complex arrangement. 8)

I got home from work early enough to run The Dirt Rat 2. I think I'm gonna like this bike. It appears my exhaust repair is solid. :D

I found a good deal on some new reproduction plastic. I ordered a can of correct Honda Flash Red paint for the frame, and a new blue (the correct color) seat cover. I already have some black semigloss engine paint, and silver wheel/rim paint to use on the swingarm. Add in some new decals, and an hour or two sanding and polishing the tank and this bike should look OK. :P

I know, waste of time and money, but it makes me happy and it's harmless... :wink:

That's hardly a waste! You'll get nothing but support from this community. :D

Where did you find repro plastic?

[SpudRider]

It's a cool but complex arrangement. 8)

I got home from work early enough to run The Dirt Rat 2. I think I'm gonna like this bike. It appears my exhaust repair is solid. :D

I found a good deal on some new reproduction plastic. I ordered a can of correct Honda Flash Red paint for the frame, and a new blue (the correct color) seat cover. I already have some black semigloss engine paint, and silver wheel/rim paint to use on the swingarm. Add in some new decals, and an hour or two sanding and polishing the tank and this bike should look OK. :P

I know, waste of time and money, but it makes me happy and it's harmless... :wink:
That's hardly a waste! You'll get nothing but support from this community. :D

Where did you find repro plastic?
X2! :D

Spud :)

[FastDoc]

The reproduction plastic is from Maier, inc. They made good stuff, better than Acerbis IMHO. At least in terms of longevity and sunlight resistance.

The paint and reproduction decals are from a small Honda dirt bike restoration company called Flash Red Paint or something like that.

The seat cover is a reproduction from a company in Oregon I found on eBay.

Total investment on the new look will be $250 with everything, so with $450 on the bike I'm still in good shape. A restored strong running XR for $750 or so ain't bad.

Then I need to fix the lights and a new speedometer cable and enjoy the ride! 8)

[Weldangrind]

Do you plan to dual sport this bike?

[FastDoc]

I don't know, probably not. It costs about $600 for a Baja Designs kit and DOT tires and paperwork... I have the KLX for that role. I see this bike more as a ride it hard and put it away wet playbike. :wink:

[FastDoc]

Don't forget to check the Ride Report section for some cool pics of Roger, FastDoc, and The Dirt Rat 2 out in the Juniper Dunes Winderness Area!

Some cool videos of much better riders jumping the sand dunes! :D

[FastDoc]

Check out this D/S kit....

Too good to be true?

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=320778659329&fromMakeTrack=true&ssPageName=VIP:watchlink:top:en

[SpudRider]

Check out this D/S kit....

Too good to be true?

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=320778659329&fromMakeTrack=true&ssPageName=VIP:watchlink:top:en
That's the Rocky Mountain ATV/MC kit, Doc. ;)

http://www.rockymountainatvmc.com/images/orprod/400/t/tus_10_mot_end_lig_kit_1285760003.jpg

http://www.rockymountainatvmc.com/vehicleSelectProd.do?prevVehicleType=2&prevMake=2&prevModel=312&keyword=tusk+dual+sport+kits&vehicleTypeId=2&make=2&model=312&applyFilter=Change+Vehicle&year=2006&navTitle=Electrical&navType=type&webCatId=20&webTypeId=193&prodFamilyId=26724&stockId=&listingId=&uri=%2FproductDetail.do

Spud :)

[Weldangrind]

Check out this D/S kit....

Too good to be true?

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=320778659329&fromMakeTrack=true&ssPageName=VIP:watchlink:top:en

Did you change your mind, Doc? Planning on dual sporting this bike?

[FastDoc]

I located that unit for Roger and his KLX. 1/3 the cost of a Baja Designs kit, and less than a person could put one together out of used/spare parts...

Only then I got to thinking...

[FastDoc]

Does anyone know if this is a good kit? It does not have a headlight but both the KLX and The Dirt Rat already have headlights. Not with the golden DOT stamp but maybe thet would pass...

[Weldangrind]

The PITA factor makes that kit worthwhile. You'd struggle to buy all the lights, the horn, the switches and the wire for that price, and it's all figured out this way.

I picked up some cheap switches and lights, and it took considerable effort to figure out how to wire them. I still don't have the horn or the flasher. I might consider this kit.

[Weldangrind]

The Polisport headlight looks reasonable, and it's a fair price: Polisport Universal DOT MMX Headlight Red 64-6915 (http://www.ebay.ca/itm/Polisport-Universal-DOT-MMX-Headlight-Red-64-6915-/300615912117?pt=Motorcycles_Parts_Accessories&hash=item45fe1acab5)

[FastDoc]

Nice find, and it's DOT!

[FastDoc]

Roger purchased the kit.

I will install it for him, and would be happy to start a picture thread about it if anyone's interested.

[SpudRider]

Roger purchased the kit.

I will install it for him, and would be happy to start a picture thread about it if anyone's interested.
Please do start a new thread on this subject! :D

Spud :)

[Weldangrind]

Roger purchased the kit.

I will install it for him, and would be happy to start a picture thread about it if anyone's interested.

I'm quite interested. Thanks for the offer.

[FastDoc]

I couldn't resist. I have begun to restore The Dirt Rat;-). All new plastics, I have refinished the tank, and new seat cover. New color matched frame paint, sswingarm paint and decal kit. Film at 11.

[MICRider]

I couldn't resist. I have begun to restore The Dirt Rat;-). All new plastics, I have refinished the tank, and new seat cover. New color matched frame paint, sswingarm paint and decal kit. Film at 11.

Anxiously awaiting the pics, I'm betting it looks like a new bike! 8)

[SpudRider]

I couldn't resist. I have begun to restore The Dirt Rat;-). All new plastics, I have refinished the tank, and new seat cover. New color matched frame paint, sswingarm paint and decal kit. Film at 11.
Somehow, I'm not surprised. ;) Let's see photos! :D

Spud :)

[FastDoc]

I've just gotten started. I recovered the seat and it looks great. It is now the correct Honda Blue with white 'XR' logo :D .

I spent over an hour sanding the tank. What a PIA, my arms are sore! All the discoloration is gone, as are all the scratches. I started with a Scotchbrite disc in a drill end ended with 1000 grit hand wet sanding. I can't apply the resin to make it shiny yet as I'm still waiting for the tank decals and the frame paint.

Using a heat gun and much patience I removed what was left of the 28 year old decals. I think that will be it for tonight. Right now it looks terrible, all in pieces and all :cry: .

Soon I'll pull the wheels, paint the hubs and brakes, and the swingarm. Then I'll remove and repaint the exhaust, and the other black parts like the shift lever and footpegs. Then finally I'll repaint the frame best I can with the motor in place.

Putting it all together when done shouldn't take more than a half hour.

For the final touch I'm considering asking Wayne for a new set of custom 'Dirt Rat' decals. :wink:

[Weldangrind]

I'm surprised it took you this long. :lol:

[SpudRider]

I'm surprised it took you this long. :lol:
:lol:

Spud :)

[FastDoc]

I'll take some pics of the worn out looking disassembled bike tonight after work. It currently looks terrible but it will get better. :P

The Maier plastics appear to be of VERY high quality, as nice or nicer than OEM. Some slight mods will be needed, like drilling the mounting holes but other than that it looks like it will be semi-easy to set up.

The seat came out great, as did the tank.

I plan to eBay the old plastics. They seem to sell for almost as much as the new stuff cost me! My plastics are old and faded and scraped but are strong and solid and complete so they may be worth something to someone :wink: .

eBay's a PIA but sometimes a little fun too. The worst part for me is packing it up and dragging it to UPS. :?

Still waiting on the paint and tank decals.

[Weldangrind]

I hope that the tank decals stick properly for you. For whatever reason, the factory decals seem to hang on a long time, but the aftermarket units bubble.

Looking forward to pics. :D

[FastDoc]

Been so busy. Will try to get pics of it's disassembled mess soon.

The decals are cheap. If they fall off I'll replace them.

[FastDoc]

Some pics.

The Dirt Rat in progress.

Looks pretty bad now. I could use the traditional words of encouragement!

http://img.photobucket.com/albums/v25/maule/DSC07891.jpg

http://img.photobucket.com/albums/v25/maule/DSC07887.jpg

http://img.photobucket.com/albums/v25/maule/DSC07886.jpg

http://img.photobucket.com/albums/v25/maule/DSC07885.jpg

http://img.photobucket.com/albums/v25/maule/DSC07884.jpg

http://img.photobucket.com/albums/v25/maule/DSC07875.jpg

http://img.photobucket.com/albums/v25/maule/DSC07873.jpg

Note the hole worn THROUGH the shifter lever tip!

http://img.photobucket.com/albums/v25/maule/DSC07872.jpg

Note the area with the plastic restorer resin on it vs. the dull but smooth sanded finish elsewhere.

http://img.photobucket.com/albums/v25/maule/DSC07871.jpg

Lots of bits...

http://img.photobucket.com/albums/v25/maule/DSC07870.jpg

I think I'll paint this.

http://img.photobucket.com/albums/v25/maule/DSC07869.jpg

This too.

[FastDoc]

http://img.photobucket.com/albums/v25/maule/DSC07862.jpg

Speedo sensor and magnet.

http://img.photobucket.com/albums/v25/maule/DSC07861.jpg

http://img.photobucket.com/albums/v25/maule/DSC07860.jpg

http://img.photobucket.com/albums/v25/maule/DSC07859.jpg

Decals removed getting ready for paint.

http://img.photobucket.com/albums/v25/maule/DSC07858.jpg

I plan to repaint the engine cases.

http://img.photobucket.com/albums/v25/maule/DSC07857.jpg

http://img.photobucket.com/albums/v25/maule/DSC07856.jpg

http://img.photobucket.com/albums/v25/maule/DSC07855.jpg

http://img.photobucket.com/albums/v25/maule/DSC07854.jpg

http://img.photobucket.com/albums/v25/maule/DSC07853.jpg

The plastic will be going up on eBay.

http://img.photobucket.com/albums/v25/maule/DSC07852.jpg

The very old with the new shiny Maier fender :D .

http://img.photobucket.com/albums/v25/maule/DSC07851.jpg

http://img.photobucket.com/albums/v25/maule/DSC07849.jpg

http://img.photobucket.com/albums/v25/maule/DSC07848.jpg

[FastDoc]

http://img.photobucket.com/albums/v25/maule/DSC07846.jpg

http://img.photobucket.com/albums/v25/maule/DSC07844.jpg

And a pic of Little Sweetie so we can see something beautiful rather than this old dirt bike :? .

http://img.photobucket.com/albums/v25/maule/DSC07883.jpg

PLUS I finally got the KLX de-mudded! :roll:

http://img.photobucket.com/albums/v25/maule/DSC07881.jpg

[Weldangrind]

Excellent work on the tank! Please tell us more about the plastic restoring resin; what is the brand name? Where do you find it?

The Maier stuff looks really good, and you can choose to not install the tail light if you wish.

The header is a good candidate for electrolytic de-rusting.

Got a pic of the seat?

[Weldangrind]

BTW, are you certain that hole in the shifter is worn through? I have a shifter with a similar hole (in a different spot) that is the spring anchor hole. The rest of the bike doesn't look anywhere near that worn.

[SpudRider]

Maier plastic has a very good reputation, and I now know why. ;) Your new rear fender is beautiful. :)

Spud :)

[FastDoc]

http://img.photobucket.com/albums/v25/maule/DSC07876.jpg

Here's the seat.

I'll post info on the plastic restoration kit soon. It takes time and energy to sand and sand and sand and sand... but the result is excellent.

[MICRider]

The new fender looks awesome! I'll have to check out their website, looks like top quality stuff! Lol, I'm anxious to see the final product, I have a sneaking suspicion that it will look like a brand new bike! 8)

[FastDoc]

Excellent work on the tank! Please tell us more about the plastic restoring resin; what is the brand name? Where do you find it?

The Maier stuff looks really good, and you can choose to not install the tail light if you wish.

The header is a good candidate for electrolytic de-rusting.

Got a pic of the seat?

The header is not rusty, just baked on dirt.

I'm not going to use the stock taillight or tool bag. If I D/S the bike later it will use a different taillight anyways.

[Weldangrind]

I'm guessing that your bike has a 12 volt system, so you should be ok with just a headlight. I read on another forum (Thumpertalk maybe?) that the six volt system in the early XR200R required a functional tail light, or else the headlight would burn out quickly.

I no longer need to worry about that with Son of Weldangrind's XR200R, because the China motor has a modern 12 volt system. :D

[FastDoc]

Thanks for the tip, Weld!

[FastDoc]

Made some progress tonight. Worked on it for about 4 hours alongside helping Roger dualsport his KLX. I will post a seperate tread on that also :D .

http://img.photobucket.com/albums/v25/maule/DSC07918.jpg

A mockup of the new seat and side panel.

http://img.photobucket.com/albums/v25/maule/DSC07916.jpg

Swingarm painted.

http://img.photobucket.com/albums/v25/maule/DSC07915.jpg

Engine painted.

http://img.photobucket.com/albums/v25/maule/DSC07914.jpg

Mudguard painted.

http://img.photobucket.com/albums/v25/maule/DSC07912.jpg

Chainguard painted.

http://img.photobucket.com/albums/v25/maule/DSC07910.jpg

http://img.photobucket.com/albums/v25/maule/DSC07909.jpg

Sprocket painted.

http://img.photobucket.com/albums/v25/maule/DSC07908.jpg

Rear brake serviced and painted.

http://img.photobucket.com/albums/v25/maule/DSC07907.jpg

http://img.photobucket.com/albums/v25/maule/DSC07906.jpg

Zillion BTU diesel powered shop heater. Toasty. 8)

[FastDoc]

http://img.photobucket.com/albums/v25/maule/DSC07905.jpg

http://img.photobucket.com/albums/v25/maule/DSC07904.jpg

http://img.photobucket.com/albums/v25/maule/DSC07896.jpg

http://img.photobucket.com/albums/v25/maule/DSC07893.jpg

Some more 'before' pictures.

[FastDoc]

Looking at the pics I'll have to reconsider my idea to not paint the cylinder head. In real light, without the flash, there does not appear to be such a different between the painted and unpainted surfaces.

[Weldangrind]

What paint do you use on the swingarm?

[SpudRider]

What paint do you use on the swingarm?
X2! The swingarm looks beautiful! :D How did you clean/prepare the surface for painting?

Spud :)

[FastDoc]

I made a little more progress today. I think I am withing 3 hours of being finished :wink: .

The Maier plastics required minor fitting. No biggie. I painted the rest of the engine. It was a good decision and the outcome looks excellent. I replaced the rear wheel and installed the swingarm decals.

The paint I used is made for wheels. It is a perfect match for Honda swingarms and very easy to apply well and it holds up great. This is still leftover from when I repainted the wheels for my 1989 Ford Probe GT. I still miss that car, I never should have sold it but that's a different story :cry: .

http://img.photobucket.com/albums/v25/maule/DSC07948.jpg

http://img.photobucket.com/albums/v25/maule/DSC07947.jpg

Some of the plastics fitted.

http://img.photobucket.com/albums/v25/maule/DSC07946.jpg

Just a mock up. I won't install the palstic until after I paint the frame.

http://img.photobucket.com/albums/v25/maule/DSC07945.jpg

http://img.photobucket.com/albums/v25/maule/DSC07943.jpg

http://img.photobucket.com/albums/v25/maule/DSC07940.jpg

http://img.photobucket.com/albums/v25/maule/DSC07938.jpg

http://img.photobucket.com/albums/v25/maule/DSC07937.jpg

http://img.photobucket.com/albums/v25/maule/DSC07936.jpg

http://img.photobucket.com/albums/v25/maule/DSC07935.jpg

http://img.photobucket.com/albums/v25/maule/DSC07934.jpg

http://img.photobucket.com/albums/v25/maule/DSC07933.jpg

Little Sweetie got a new petcock today. The old one was partially clogged on Main and Reserve was 100% blocked. The new one flows better, the bike runs great, and the reserve position works :D .

http://img.photobucket.com/albums/v25/maule/DSC07951.jpg

It was warm today so I took her for a ride and then winterized her. She sleeps next to Betty the GS750. A spot is reserved for the BSA :roll: .

[SpudRider]

The bike looks great! The Maier plastic is beautiful. :) How did you prepare the engine for painting?

Spud :)

[FastDoc]

Powerwash then tooth brush and paint brush with mineral spirits.

I'm only after good, not coucours :wink: .

If you do your KLX this winter Spud I'd recommend pulling the motor. By the time I had masked the frame to paint the engine, and vice-versa, I could have removed the engine and done a better job in the process :? .

If you paint the KLX's frame I'd recommend an epoxy or similar high quality paint. For the motor I'd use a silver basecoat/clearcoat engine paint :D .

For all the black bits good old Plasitkote :P .

For the rims I found fine steel wool and mineral spirits to polish them nicely.

New plastic and some decals and you're good to go.

[Weldangrind]

Thanks for the tips. I never thought of fine steel wool for aluminum rims.

Where did you find the swingarm decals?

[FastDoc]

eBay for like $7 delivered in a regular 1st class envelope.

[FastDoc]

The paint is on. It's a high quality epoxy and I suspect it should hold up well. The match is perfect. It's already dry but I'll try to wait till tomorrow to really let it cure before I unmask it :P .

Then it's a simple matter of bolting on the exhaust, footpegs, shifter, skid plate, tank and seat and I'll be done.

Sorta.

I think the gaiters can stand a refinish as well. :wink:

The tank looks as shiny as new. :D

http://img.photobucket.com/albums/v25/maule/DSC07962.jpg

I have some black leather/vinyl dye that should clean these right up.

http://img.photobucket.com/albums/v25/maule/DSC07961.jpg

http://img.photobucket.com/albums/v25/maule/DSC07960.jpg

http://img.photobucket.com/albums/v25/maule/DSC07959.jpg

http://img.photobucket.com/albums/v25/maule/DSC07958.jpg

This is the product I used.

http://img.photobucket.com/albums/v25/maule/DSC07957.jpg

http://img.photobucket.com/albums/v25/maule/DSC07956.jpg

http://img.photobucket.com/albums/v25/maule/DSC07963.jpg

[Weldangrind]

How did you apply the paint? Compressor or spray bomb?

Might as well go all the way and polish the skid plate. :D It'll be really easy to clean if you do.

[FastDoc]

I DID polish the skidplate :oops: .

[FastDoc]

Some quick low quality cellphone pics I took this AM while rushing out the door.

It really looks great :P . Much better than I thought it would, thank God. I now pray the new paint holds up well, especially the engine. The engine paint is good for 500 degrees so I figure it will be fine.

BTW, there were no exhaust gaskets in the head when I took it apart, so I put it back together the same way. Assuming it does not leak, can I leave it that way?

Also the new plastic, like the old, did not have any heat insulation on the inside of the right side cover. Should I fabricate something> I was just thinking about 10-20 layers of aluminum foil and some duct tape or contact cement.

http://img.photobucket.com/albums/v25/maule/5-48.jpg

http://img.photobucket.com/albums/v25/maule/4-61.jpg

http://img.photobucket.com/albums/v25/maule/3-74.jpg

http://img.photobucket.com/albums/v25/maule/2-85.jpg

http://img.photobucket.com/albums/v25/maule/6-43.jpg

[Weldangrind]

That looks like a brand new bike!

You can leave the exhaust without gaskets if you wish, but it will always leak a little. Not a problem with denim, but nylon riding pants will melt. I bet that if you remove the header and look into the exhaust port, you'll find very compressed metal gaskets that have become one with the head. If there are no gaskets at all, it might make a mess of your freshly painted head and cylinder.

Do you still have a pile of XR200 parts in the corner? If so, look on the back of the right side cover and see if there is a heat shield there. You could always bond it to the Maier cover.

[FastDoc]

No heat shield on the old cover. I may still make one out of foil and glue or tape though to be on the safe side.

Looking at pics I took of the exhaust ports I think there is an old gasket squashed in there. I'll start it and see if it leaks. If I cant feel anything I'll let it be. If it dodes leak I'll order some new gaskets.

The pics don't do it justice. It really does look like an (almost) new bike. I'll take some better pics soon, likely Wednesday.

[FastDoc]

BTW, any leads on a clear vinyl tape or something I can use to protect the paint on the frame from future wear? I'd like to use some on the KLX also.

[fishman10]

doc how bout that clear stuff they sell at pep boys for along the bottom edge of cars for stone and chip protection?its kinda like wide tape. BTW both hondas are gorgeous ,,I found lil sweeties twin in an elderly gentlemens shed .. He had died ,,,and the family sold it to me,,,,I restored it enough to ride .Then I foolishly sold it ,,,,,,ah it was fun!

[FastDoc]

Thanks for the tip! I'll check the local autoparts store.

Thanks for the compliment also. I don't think I'll be selling Little Sweetie. I'm sure she'd be on the (not so) short list of vehicles I've regretted selling.

Two 1972 V8 Chevelles.
1972 Cadillac with 500 cubic inch V8.
The original Dirt Rat.
1985 RZ350.
1989 Ford Probe GT.
1990 Ninja 1100.
Two KLR650's.
1978 Fiat 131 Mirafiori.
1972 Fiat 850 Spyder.

God only knows what else I miss but there's a partial list. :wink:

[fishman10]

Also pep boys and others sell that thick foil with adhesive backing for making heat shields,,,,I,ve used it many times on atvs and dirtbikes.

[FastDoc]

Great tip. We don't have Pep Boys here but we have O'Reiley which I think is pretty much the same idea.

[MICRider]

Dang! That thing looks like brand new! Guess you'll have to think up a new moniker for it, Dirt Rat 2 doesn't really fit such a clean looking bike. Awesome job Doc, it's beautiful! 8)

[FastDoc]

Thanks MIC. :D

I plan to clean up the handgrips, dye the gaiters, and maybe repaint the triple clamps. Then I'll call it Done. 8)

Then, after it's all clean, I plan to cover it with Washington Desert Dust to my heart's content! :P

[SpudRider]

Wow! The bike looks fantastic, Doc! You did an excellent job. :D

Spud :)

[FastDoc]

The Dirt Rat 2 is done :D

What do you think, guys?

http://img.photobucket.com/albums/v25/maule/DSC07975.jpg

http://img.photobucket.com/albums/v25/maule/DSC07974.jpg

http://img.photobucket.com/albums/v25/maule/DSC07973.jpg

http://img.photobucket.com/albums/v25/maule/DSC07972.jpg

http://img.photobucket.com/albums/v25/maule/DSC07971.jpg

http://img.photobucket.com/albums/v25/maule/DSC07970.jpg

http://img.photobucket.com/albums/v25/maule/DSC07969.jpg

http://img.photobucket.com/albums/v25/maule/DSC07968.jpg

http://img.photobucket.com/albums/v25/maule/DSC07967.jpg

http://img.photobucket.com/albums/v25/maule/DSC07965.jpg

http://img.photobucket.com/albums/v25/maule/DSC07964.jpg

http://img.photobucket.com/albums/v25/maule/DSC07976.jpg

Refer back to Page 1 of this thread for the 'Before' pics. Quite a transformation. :wink:

[Weldangrind]

Ultra sano, my friend! That looks like a brand new bike (I know, I already said that). Son of Weldangrind was drooling over the pics with me. He noted that you and he chose the same grips.

On a constructive criticism note, it appears that your chain might be a tad tight.

[FastDoc]

Thanks Weld.

There is a lot more that could be done if a guy wanted to but I don't want to go (too) overboard! I have to remind myself its just an ordinary old dirt bike. Plus, somewhere down the road, it's gonna need a top end. It smokes a little, but not enough most people would notice and it does not oil up the plug or the exhaust. Maybe next year I'll do a top end on it.

I'll be sure to replace the valve seals as well :wink: .

The grips came on the bike, I just cleaned them up.

I think the chain is good. It has about 1 1/2 inches of play in it. When I sit on the bike and compress the suspension I reach down and confirm that the chain is not taught. I'll recheck it before I ride.

This weekend is supposed to be sunny but cold here. Maybe I'll get a ride in.

Maybe I'll carry a small 12 volt battery in a backpack so I can run my electric gloves and vest...

[FastDoc]

BTW what looks like red overspray on the swingarm and engine is not. It's just dust from sanding and preparation. It blows right off.

[Weldangrind]

You can certainly replace the valve stem seals without doing rings; it's very likely that new seals will solve the oil consumption. I once changed valve stem seals on a buddy's '82 Accord, and it was killing mosquitoes for miles. The seals cured it completely. Despite being a very worn and neglected car, I could still see the original cross-hatch pattern on the cylinder wall, and there was no ridge. Gotta love old Hondas.

It would cost you the seals and a head gasket. A new valve cover gasket is optional.

[SpudRider]

The transformation is wonderful! The bike looks great! :D

Spud :)

[FastDoc]

I got to ride The Dirt Rat 2 a bit today. This getting dark at 4:30 thing really sucks :evil: .

Since I bought it the rear suspension had an annoying squeak. I didn't worry about it because the bike has grease fitting in 3 places on the linkage and on the swingarm 8) .

So I greased it up best I could and it still Squeaked :cry: ! Loud! You could hear it with the engine on :oops: .

So It was time to remove the shock linkage and swingarm. I cleaned it all up good and greased it directly. A big PIA (maybe 2 hours) but it was worth it. The grease from the fittings simply did not reach where it needed to be.

Now it rides squeak free, and I have the assurance that it is all well lubricated and the bearings are good with no play at all.

[MICRider]

Wow! 8O Hard to believe it's even the same bike! Awesome job Doc! 8)

[Weldangrind]

If the squeaking returns, you'll need to replace the bearings, which would require a hydraulic press. I bought a little 12 ton press, and it's my second favourite tool in the shop. I bought a bearing kit on eBay for my '96 XR250R, and I think the brand was All Balls.

[FastDoc]

All Balls makes good stuff.

I think the bearings are fine. When properly greased they moved perfectly smooth and quietly with no play at all.

[FastDoc]

Took The Dirt Rat 2 for a long ride today. We did about 40 miles. The bike is a blast. Indeed I need a bigger challenge than The Hill Of Doom. It's too easy!

Part of the reason is the cooler weather has greatly improved the local trails, not so dusty any more. Great traction and much 'cleaner'. This is prime local dirt bike riding season right now :P .

http://img.photobucket.com/albums/v25/maule/DSC07980.jpg

http://img.photobucket.com/albums/v25/maule/DSC07979.jpg

http://img.photobucket.com/albums/v25/maule/DSC07978.jpg

http://img.photobucket.com/albums/v25/maule/DSC07977.jpg

It was SEVENTY DEGREES today! Finally some GW!!! I don't expect it to last though.

Here's something you don't see every day. Cattle dining on the pumpkin patch. Odd.

http://img.photobucket.com/albums/v25/maule/DSC07982.jpg

http://img.photobucket.com/albums/v25/maule/DSC07981.jpg

http://img.photobucket.com/albums/v25/maule/DSC07983.jpg

[SpudRider]

I love the Honda, XR series bikes! :) The Honda CRF bikes are not nearly as robust as the old, XR series bikes. ;)

Spud :)

[FastDoc]

I love the Honda, XR series bikes! :) The Honda CRF bikes are not nearly as robust as the old, XR series bikes. ;)

Spud :)

Does that also apply to the CRF230? That one is aircooled and I thought it was basically a modernized electric start XR.

I know the high strung 4 stroke motocrossers are very maintanece intensive and expensive to rebuild.

[Weldangrind]

The CRF230 is essentially the same platform as an XR200R, with the addition of electric start; it's a two-valve head. As I understand it, it is made in Brazil.

[SpudRider]

The CRF230 is essentially the same platform as an XR200R, with the addition of electric start; it's a two-valve head. As I understand it, it is made in Brazil.
Thanks for the information, Weld. :) I'm glad to know the CRF230 is not as "high strung" as the other, CRF series bikes. ;)

Spud :)

[Weldangrind]

It's also the same platform as our beloved Honda clone China bikes.

[FastDoc]

I got to ride The Dirt Rat 2 a couple of hours yesterday and I'm getting ready to leave the house with it again soon.

These XR's can really take it. I'm enjoying this bike.

It looks better all dusty than it did clean. :wink:

[FastDoc]

Had a great ride but my cat food can repair did not hold up. I glued on a heavier piece of metal. If that fails will see if Ron can weld it but I don't think so. The metal is pretty frail and he's not the best welder :roll: .

I might have to get a 'new' one but the ones I see on CL are all pretty shabby and expensive.

I wonder if the new muffler I took off the KLX could be made to fit?

[Weldangrind]

Yeah, probably, but steel is easy and cheap. When I built the muffler for the XL250S I had, I cut away all of the cancerous material, which eliminated the entire muffler portion. On the late 70's / early 80's XR / XL engines, there is usually a large chamber in the midpipe section that my buddy says looks like a cow organ (I agree). It transitions to a cylinder for the muffler section, and that has a bracket that attaches to the frame under the seat.

If your muffler fits that description, the fastest solution is to chop off the entire cylindrical section and replace it with new exhaust tubing. With the XL, I cut the exhaust tubing to match the length of the original muffler and welded it in place. I then welded the bracket on top. What you don't realize is just how bad the muffler is inside, by the time it rusts through.

I found a piece of tubing that is the same size as the midpipe (before the cow organ section), and I used that for the exit pipe. It simply extends into the muffler about 4", and it is capped. The perimeter of the pipe is then drilled full of holes that add up to the same area as the exit pipe. I cut a piece of flat plate that is a little thicker than the exhaust tubing, and cut it into a circle to fit the end of the muffler. A hole in the center of the plate accomodates the exit tube. Finally, the exit tube is welded to the end cap, and the end cap is welded to the exhaust tube. IMHO, it sounded just right on the XL.

For review:

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06020.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06020.jpg)

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06022.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06022.jpg)

http://i158.photobucket.com/albums/t109/Weldangrind/XL250S/DSC06026.jpg (http://s158.photobucket.com/albums/t109/Weldangrind/XL250S/?action=view&current=DSC06026.jpg)

Make sense?

[MICRider]

Hey Weld, I think that muffler is a work of art :). You didn't use any kind of packing in it did you? I remember the bike sounded great in the vid and not overly loud.

[Weldangrind]

Thanks Stew. :D

Nope, no packing, just like the original Honda muffler. It sounded great to me, and more importantly, to the new owner.

[FastDoc]

Maybe I can hire you for a rebuild? :P

[SpudRider]

You did a beautiful job on that muffler, Weld! :D

I'm sorry to hear your muffler is not "purring" any more, Doc. :(

Spud :)

[Weldangrind]

Maybe I can hire you for a rebuild? :P

PM sent.

[FastDoc]

You did a beautiful job on that muffler, Weld! :D

I'm sorry to hear your muffler is not "purring" any more, Doc. :(

Spud :)

More of a roar, I'm afraid.

I have it glued up again for the time being, pending an expert rebuild :D .

[FastDoc]

Maybe I can hire you for a rebuild? :P

PM sent.

Thank you Brother Weld. :D

[Weldangrind]

You did a beautiful job on that muffler, Weld! :D

I'm sorry to hear your muffler is not "purring" any more, Doc. :(

Spud :)

More of a roar, I'm afraid.

I have it glued up again for the time being, pending an expert rebuild :D .

If you find an expert, you should hire him. Until then, I'm happy to be your welding hack.

[FastDoc]

SCORE:

Muffler.

http://kpr.craigslist.org/mcy/2746548510.html

[SpudRider]

Nice find! :D

Spud :)

[MICRider]

SCORE:

Muffler.

http://kpr.craigslist.org/mcy/2746548510.html

Sweet! Excellent price as well! :D

[Weldangrind]

Really good score! I hope you grab it today.

[FastDoc]

Will the muffler for an 86 fit my 84?

The part numbers for the insert to reduce noise are off by '1' on Bike Bandit. There is no part number for the 84 muffler but there is one for the 86.

[Weldangrind]

Will the muffler for an 86 fit my 84?

The part numbers for the insert to reduce noise are off by '1' on Bike Bandit. There is no part number for the 84 muffler but there is one for the 86.

Uncharted territory. It could be made to fit, if it doesn't. There is a subtle difference between the '83 and '84, but I'd guess that the '86 frame is virtually the same. You could always resell the muffler for a profit on eBay.

[FastDoc]

I checked it out. It was in good shape but the mounting hole was in the wrong place. I've gotta learn to weld and grind, this would have been an easy force-fit. :wink:

[FastDoc]

I broke down and bought it as my existing muffler was falling apart.

It fit pretty easily but I needed to drill another hole in the rear mounting tab on the muffler and the front mount did not line up so I fabricated a simple bracket.

Heres the problem.

The new muffler does not have a sealing gasket and I can't remove the old one without destroying it. Right now I have it sealed with a couple of wraps of Gorilla tape. I don't know if that will last or not... probably not so I need to order a new gasket.

The part numbers and prices for the '84 (my bike) and the '86 (the muffler) are not the same. Which should I get? I'm leaning towards the '86.

A nice bonus is it cured my off idle flat spot. I thought it was a carb issue but all the holes in the muffler must have been making it run off a tad. It sounds better too leading me to blieve my old muffler was rotted on the inside as well as the outside.

[katoranger]

The xr80 muffler was completely hollow inside when I opened it up. Just some remnants of a baffle.

[FastDoc]

I will cut mine open to see. I bet it's similar.

[Weldangrind]

I guarantee that the interior of the muffler is rotten. They start from the inside and work outwards.

I'd try the '86 gasket, but have you measured the '84 gasket OD? You should be able to confirm whether or not the '84 gasket would work.

[FastDoc]

I got it done Weld. I was able to carefully remove the '84 gasket and it's all great now. :D

[Weldangrind]

Are you still gonna do an autopsy on the old muffler?

[FastDoc]

I think I tossed it already. It occured to me that to cut it open with my angle grinder would have made a mess so I didn't bother.

[Weldangrind]

Too bad. The clamp area could be welded onto a new pipe and resold. I used an old clamp with new pipe to fabricate Son of Weldangrind's XR200R exhaust.