Abunch of Lifan XR200 pictures

[FastDoc]

I told you it was filthy.

http://img.photobucket.com/albums/v25/maule/DSC06313.jpg

The Lifan XR.

http://img.photobucket.com/albums/v25/maule/DSC06312.jpg

Some random shots of the garage, though you all might be interested in the toys. Being single and employed is nice.

http://img.photobucket.com/albums/v25/maule/DSC06311.jpg

The well restored 1981 Yamaha XS400. Great little bike.

http://img.photobucket.com/albums/v25/maule/DSC06309.jpg

The flagship Honda.

http://img.photobucket.com/albums/v25/maule/DSC06308.jpg

The Mighty Q.

http://img.photobucket.com/albums/v25/maule/DSC06307.jpg

My shop is usually a lot neater than this!

http://img.photobucket.com/albums/v25/maule/DSC06306.jpg

Bill's drowned solenoid. It works!

http://img.photobucket.com/albums/v25/maule/DSC06305.jpg

Chinatools (HF) for a Chinabike!

http://img.photobucket.com/albums/v25/maule/DSC06303.jpg

On/off works, have to sort out the starter button.

http://img.photobucket.com/albums/v25/maule/DSC06302.jpg

I won't be able to run a countershaft sprocket cover.

http://img.photobucket.com/albums/v25/maule/DSC06300.jpg

Not fully installed.

http://img.photobucket.com/albums/v25/maule/DSC06299.jpg

Good solid grounds.

http://img.photobucket.com/albums/v25/maule/DSC06298.jpg

Good connections. The tape is just labels, removed already.

http://img.photobucket.com/albums/v25/maule/DSC06296.jpg

http://img.photobucket.com/albums/v25/maule/DSC06293.jpg

Battery for a Harley.

http://img.photobucket.com/albums/v25/maule/DSC06290.jpg

USPS's treatment of my package of electrical bits.

http://img.photobucket.com/albums/v25/maule/DSC06288.jpg

A bird Martin The Cat killed while I was working on the bike.

http://img.photobucket.com/albums/v25/maule/DSC06288.jpg

[FastDoc]

Martin's bird.

http://img.photobucket.com/albums/v25/maule/DSC06315.jpg

[FastDoc]

Cheezy cellphone video but its kinda fun.

http://img.photobucket.com/albums/v25/maule/th_video-2010-10-26-21-35-55.jpg (http://smg.photobucket.com/albums/v25/maule/?action=view&current=video-2010-10-26-21-35-55.mp4)

[SpudRider]

Thank you for the photos, and video, Bill! :D The Lifan engine looks great; you have done a superb job. :)

Spud :)

[mizke]

nicely done doc, seeing over the time you have had this project going just how much you have had to take apart on the bike. i must say some powder coating sure would look good. the swingarm would look good black with the red frame.. and i love the garage

seems when it comes to placement of tools during a project we have the same process. set it down and leave it untill the job is over.. i find i like to leave the tools out untill the project is done with.. makes finding the right tool quicker..

you have inspired me, this winter along with the rear end rebuild of my quad im going to redo my wiring with larger higher quality wires.

and about the starter button, if you wanted to do this and feel you have the ability to do it. you can take the switch housing apart and just completely redo and run your own wiring for the starter button..

[Weldangrind]

I won't be able to run a countershaft sprocket cover.

http://img.photobucket.com/albums/v25/maule/DSC06300.jpg

I don't get it. Is the new sprocket that much thicker? If so, I presume that's because the XR uses a 520 chain, while the Lifan likely uses a 428. Could the XR cover fit over the countershaft sprocket?

[mizke]

a peice of angle iron, grinder with cut off wheel, and a saturday afternoon. i bet you could make a custom cover..

[SpudRider]

I don't understand either, Doc. Can't you trim the sprocket cover enough to clear the frame? :?: I think the bike will look fine without a sprocket cover, but I can't visualize the problem. ;)

Spud :)

[katoranger]

Sounds really nice with that stock exhaust. My xr looks to be in about the same condition. Maybe alittle better as I found it under a lean to.

[FastDoc]

I don't understand either, Doc. Can't you trim the sprocket cover enough to clear the frame? :?: I think the bike will look fine without a sprocket cover, but I can't visualize the problem. ;)

Spud :)

Its the frame in the way not the sprocket :? . I used an angle grinder on it quite a bit last night. I suppose it can be done I just ran out of patience, I'll try some more later.

The battery and air filter are in. I may have it on the road/trail in the next couple of days. The battery will be taped in until my friend Ron gets home from his long distance trucking run. He's the welder...

He also has a pneumatic staple gun I'll need to install the seat cover.

If all goes well, and she's a good runner, I MAY strip it down and repaint the frame and swingarm. I already have a stock painted metal tank in good shape, and some new grips. I may break my rule and un-uglify it....

[katoranger]

Doc, I think you need to make an investment.

I use one of these. I don't know what I am doing, but it pretty much runs itself. The 140 has the gas shielding setup, but it will also run fluxcore wire which I what I use. I got my used off ebay. :wink:

http://www.tractorsupply.com/welding-metalworking/welders/mig-welding/mig-welders/hobart-handler-140-welder-3812040

The cheaper ones are fine, but do not have all the different settings which help for welding thin stuff.

If you can work the glue gun you can weld.

[Weldangrind]

I think I get it now. The Lifan cover won't accomodate the XR swingarm mounting point. Hopefully a little trimming will solve it. You'd hate for Miss Megan to get her pants caught in the chain. 8O

Rather than installing a metal tank, you could wet sand the plastic tank with progressively finer grits. Once it's smooth, rub some clear silicone spray into it, and it will retain a semi gloss look that is easy to clean.

[katoranger]

I would wait on the repaint. Nice not having to worry about it being scratched up from the likely drops coming up.

[Weldangrind]

Doc, I think you need to make an investment.

I use one of these. I don't know what I am doing, but it pretty much runs itself. The 140 has the gas shielding setup, but it will also run fluxcore wire which I what I use. I got my used off ebay. :wink:

http://www.tractorsupply.com/welding-metalworking/welders/mig-welding/mig-welders/hobart-handler-140-welder-3812040

The cheaper ones are fine, but do not have all the different settings which help for welding thin stuff.

If you can work the glue gun you can weld.

That Hobart is a nice machine, but it lacks the variable voltage control of this one: http://www.eastwood.com/mig-welder-110vac-135a-output.html

[katoranger]

That is a good buy there. A welder is definately an investment. I have made enough money fixing things for people to pay for mine.

Repaired alot of mower decks.

When I get a real shop, I may start using the gas setup.

[Weldangrind]

I use gas only. I now have a bottle of tri-mix on the side for when I need to stick stainless together.

[davidsonsgccc]

im glad your getting it worked out. i like following modification progress.

[katoranger]

I am not yet that experienced. All of my welding is done outside too.

[FastDoc]

I'm very excited. :D

It turns out that a Q/DR200SE battery will fit snugly inside a gutted XR200 airbox! :!:

Since I'll be running a Uni filter I don't need the Honda airfilter, and my battery location problem is all but solved.

I'll take some pics. :P

[mizke]

awsome, man i think if i ever get to take on a project like this. it might turn out to be some what addicting to the point of always looking for a project and once its finished keep it or sell it for a slight profit

[FastDoc]

It is addicting.

I make more money in an hour or two at the office than I can profit off this bike but I like the project, and having you all along for the ride.

[mizke]

you sure that battery is going to be ok laying down on its backside like that ?

like i said in your other thread in the forum, you should go all out for a show room quality restoration.. new bolts, new bushings, get the frame and swingarm powder coated, some protaper bars, new grips and maybe give it to your lady friend as a birthday or xmas present since xmas is right around the corner.. i bet you would be the first guy to give her something like a dirt bike, and who knows doc she might dig the bike enough she would want to go for her bike license and you 2 can then ride together..

[katoranger]

It is addicting.

I make more money in an hour or two at the office than I can profit off this bike but I like the project, and having you all along for the ride.

You probably would be able to get your money spent out and thats about it.

[Weldangrind]

Not in BC. http://vancouver.en.craigslist.ca/rds/mcy/2031253703.html

That seller will likely get what he's asking.

[FastDoc]

you sure that battery is going to be ok laying down on its backside like that ?

like i said in your other thread in the forum, you should go all out for a show room quality restoration.. new bolts, new bushings, get the frame and swingarm powder coated, some protaper bars, new grips and maybe give it to your lady friend as a birthday or xmas present since xmas is right around the corner.. i bet you would be the first guy to give her something like a dirt bike, and who knows doc she might dig the bike enough she would want to go for her bike license and you 2 can then ride together..

Its a gel battery. Nonvented. It can be mounted in any posistion. It's supposed to be much smaller lighter and tougher than a wet battery too.

I need to cut a block of styrofoam to fill the gap below it for extra support though.

[FastDoc]

It is addicting.

I make more money in an hour or two at the office than I can profit off this bike but I like the project, and having you all along for the ride.

You probably would be able to get your money spent out and thats about it.

Everything included, I'm out about less than $500. It would have been a lot more if not for the help of my fellow Chinariders.

The CL ad will read something like,

"1983 Honda XR200R. BRAND NEW ENGINE. Not rebuilt, brand new. The rest of the bike is fully refurbished mechanically. Electric start too. $1,250 OBO."

I bet it sells fast!

[FastDoc]

As far as Miss Meagan goes, I'd be better off buying her a new Q for Andy's cost (just over $1,000) and saving the immense amount of time required to make this old XR shine. That said, this will be a good bike for the Montana Cowgirl to learn on.

[FastDoc]

The airfilter is set aside, along with a box of other sundry extras, ready to be picked up whenever you like. :D

[Weldangrind]

Thanks Doc! :D

[katoranger]

All cleaned up and ready to ride it would be a steal at $1200. Of course that means spending alot more time and some more money.

[mizke]

having the frame powder coated and the swingarm powder coated would be under 300. if you did that, replaced all the nuts and bolts with brand new ones, and got new plastics or did a good job painting the stockers and got her cleaned up.. id pay 1500 for it if i was in the market for it.. or doc just keep it for when you get the wild hair to go out and have some real fun kicking dirt up..

[FastDoc]

Its hard for me to not make an old bike look, as well as run good, so I figure just give me some time... :D

[mizke]

lol same way as me, getting running good and think. oh im done sweet.. a few weeks later you look at it and think hmm i could paint that, then it turns into a complete over haul on the looks

[FastDoc]

lol same way as me, getting running good and think. oh im done sweet.. a few weeks later you look at it and think hmm i could paint that, then it turns into a complete over haul on the looks

So true.

I am now able to declare the Lifan XR mechanically done!

It's all together and buttoned up. Starts with a push of a button and runs great.

Looks like a$$ but good for now.

There will be little things like a choke cable, a headlight bulb, handgrips, countershaft sprocket cover, fork seals, and stuff like that, but I plan to take it for a ride tomorrow. Will stop off at DOL on the way to work and get OHV stickers. :D

[katoranger]

I think I have a choke cable.

It would be a really sharp bike with a quick cleanup and paint.

[FastDoc]

I'd be interested in the choke cable if you have one.

The Lifan XR's choke lever is spring loaded with no detents. The only way to use it now is to lift the leevr and hold it up until she'll run without the choke. It's just 30 seconds or so now but it's going to get much colder soon!

[Weldangrind]

Doc, I think you're bike was a hybrid before you got your hands on it. Son of Weldangrind's XR has no choke cable (or provision for it), and your instrument cluster looks very street oriented.

We bought a new Mikuni, and we have no plans of using a choke cable.

[FastDoc]

Doc, I think you're bike was a hybrid before you got your hands on it. Son of Weldangrind's XR has no choke cable (or provision for it), and your instrument cluster looks very street oriented.

We bought a new Mikuni, and we have no plans of using a choke cable.

Its a hybrid indeed.

The instrument cluster is totally street. It even has indicators for turn signals and high beams.

I bought a seat cover for a 1983 and it does not fit, too long so I think the seat may not be original.

The frame is not what is set up for the choke cable, it's the Lifan engine that is.

I'd be happy for the choke cable.

Looks like soon we'll have 3-4 Lifan XR's around here.

I plan to go for its maiden trail ride this afternoon. :D

[Weldangrind]

That's funny. You have a Lifan powered XR, and WA has a Honda powered Lifan. :lol:

[mizke]

I'd be interested in the choke cable if you have one.

The Lifan XR's choke lever is spring loaded with no detents. The only way to use it now is to lift the leevr and hold it up until she'll run without the choke. It's just 30 seconds or so now but it's going to get much colder soon!

hey doc ebay has choke levers for china quads and bikes for extremely cheap, the hard part is finding the plate that bolts to the side of the carb to hold the choke cable..

ive been considering removing my choke cable cuz i want to shave some weight off the quad, if i do and you still need it i can send you the cable and the lever housing with my start button, light switches and what not on it.. id just need to figure out how to rewire those into normal switches

[FastDoc]

Thanks!

The carb is set up for a cable already. Will take pic when I can.

I rode The Rat 30 miles on the trails today! Wonderful! Worth the effort! Very easy to ride, comfortable and plenty of power with its dirt oriented gearing.

Here's a pic of Doc and The Rat after the ride. My friend Roger rode his XR and we switched back and forth. He enjoyed The Rat also.


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

[FastDoc]

PS I got the countershaft sprocket cover installed OK. An angle gringer made short work of the modifications needed for it to fit in the frame of the XR.

[mizke]

good looking bike you got there, some fresh paint and a nice shiney pipe on it and she will be perfect.

[FastDoc]

So far I'm happy it RUNS perfect. BTW, I am SO HAPPY I decided to go with a battery system and preserve the electric start. That will be a big selling point if and when that time comes.

[mizke]

you shouldnt sell it doc, you have a fresh motor in a dirt only bike.. doesnt get much better then that

[Weldangrind]

It looks great Doc! Would you like to do a front disc brake upgrade? I have some parts...

[FastDoc]

The Rat is running great. I trail rode 40 miles this weekend without a hitch.

The seat cover I bought is wrong, will try to send it back.

The chain and rear sprocket are shot. Since I'm leaning towards keeping it, I will order new ones. A Tsubaki and a JT, respectively. The front sprocket is new.

Does anyone know if these Honda mufflers need to be repacked? It sounds kinda meaty.

[mizke]

ahh doc just swap that can out for a new fmf one, or hmf, dg, yoshi.. add some power, a nicer sound, and hotter looks

[SpudRider]

Holy Cow! I must have accidentally unsubscribed from this thread! 8O I'm glad I discovered the problem, and got back here! :)

The "Dirt Rat" looks great, Doc! You did a superb job. :D

Spud :)

[FastDoc]

Holy Cow! I must have accidentally unsubscribed from this thread! 8O I'm glad I discovered the problem, and got back here! :)

The "Dirt Rat" looks great, Doc! You did a superb job. :D

Spud :)

Spud, I was WONDERING where you were! My feelings were getting hurt you'd hardly noticed The Rat!

[SpudRider]

Holy Cow! I must have accidentally unsubscribed from this thread! 8O I'm glad I discovered the problem, and got back here! :)

The "Dirt Rat" looks great, Doc! You did a superb job. :D

Spud :)

Spud, I was WONDERING where you were! My feelings were getting hurt you'd hardly noticed The Rat!
I'm sorry, Doc! :( I don't know how I got unsubscribed from this thread! :? In the past I have clicked the wrong "button" by mistake, and been unsubscribed from threads; I guess the same thing happened to me this time. :roll: Anyway, I am very glad to be back! Congratulations! The "Dirt Rat" looks great! You have broken new ground with this project, Brother Bill! :D

Spud :)

[Weldangrind]

Swapping on a different pipe is a challenge, since there isn't much aftermarket support for this model year. I don't think that the stock mufflers require packing, but maybe the baffle has been removed.

If you seriously want to swap the muffler for another product, let me know. I worked out a solution for Son of Weldangrind's '83, because the stock muffler was rotten.

[FastDoc]

Swapping on a different pipe is a challenge, since there isn't much aftermarket support for this model year. I don't think that the stock mufflers require packing, but maybe the baffle has been removed.

If you seriously want to swap the muffler for another product, let me know. I worked out a solution for Son of Weldangrind's '83, because the stock muffler was rotten.

The pipe is probably fine and normal, I'm just used to Q. Q is very quiet.

[mizke]

im sure the header is good, i was merely talking about the silencer.. a nice fmf, dg or hmf silencer with a quit core inscert would look great..

if doc really really wanted a head pipe, just take it to any muffler shop who does customs exhaust for cars.. they have stainless steel pipe and the means to weld it..

[katoranger]

I plan to stick with the stock unit on mine. Our trails are within city limits and close to houses. I don't need to make any more noise than necessary and power is not really that important to me. Most likely won't get past 2nd or 3rd gear.

[FastDoc]

I plan to stick with the stock unit on mine. Our trails are within city limits and close to houses. I don't need to make any more noise than necessary and power is not really that important to me. Most likely won't get past 2nd or 3rd gear.

I have a 13 tooth front/50 tooth rear sprocket. I think that's stock. With the Lifan engine she'll wind out at about 60. I've not tried since I'm still in the break in period.

It's geared low, appropiate for a dirt only machine. I bet even at 20 on the trails you'll be in 4th or 5th. Should be quiet enough.

I will check my baffle, and spark arrestor.

[katoranger]

Maybe need a 14T sprocket then. I don't need to go too fast. The trails are short and twisty. Maybe a 4 acre area that we do laps on. The 90cc stays in 2-3rd most of the time.

[Weldangrind]

A 14 tooth will give you more top end and less low end grunt. We've dropped to a 12 tooth on Son of Weldangrind's XR200R. We want a wheelie machine. :D

[FastDoc]

For where I am the 13 is just right. :D

I climbed a stupid steep long hill yesterday that gives Q fits. The Dirt Rat calmly chugged up it. Mostly in second, with a downshift to first at the top.

If the motor was broken in, and I was allowed full throttle, it wowuld have done it in second no problem.

A better rider wouldd have done it in third! :oops:

Since this bike will never see the street, a 50ish MPH top speed is more than enough.

If it was an XL, I bet it could be geared for a comfortable 65.

As always, it's too bad the China motors are not 6 speeds. That would solve this gearing issue.

Or a high low transfer case.

[FastDoc]

Here's the hill. It's much bigger in person.

http://img.photobucket.com/albums/v25/maule/3-11.jpg

[FastDoc]

Here's another hill I did yesterday. The pic is from last Spring. Hence the green and wildflowers.

This hill is steep, long (1/3 mile or so), and littered with baseball-softball sized rocks. 8O

http://img.photobucket.com/albums/v25/maule/5-4.jpg

[davidsonsgccc]

looks like youve built a pretty dependable bike congradulations.

[Weldangrind]

That hill looks plenty big to me! It's cool that the Dirt Rat will power up there.

[FastDoc]

Piece of cake. :D

An addendum to the Dirt Rat's build sheet.

The battery DID leak laying on it's side. I remounted it vertically in the old airbox. Considerable modification with a Dremel was needed on the airbox, but it's done now.

The Dirt Rat and I went out for 15 miles today after work. I ran out of light. We did The Hill again.

I really like the Dirt Rat. It's SO EASY to ride!

[SpudRider]

You did a great job restoring this bike, Bill! I am glad you are enjoying your XR200. :) Honda designs and manufactures great motorcycles; I really enjoy my XR650L. :)

Spud :)

[FastDoc]

The XR's are wonderful in their engineering, simplicity, and execution. I really appreciate this old bike. I'm irritated with myself for having to remount the battery vertically. That was a redundant 1 1/2 hours I didn't need. Oh well. Blazing a new trail here!

[SpudRider]

The XR's are wonderful in their engineering, simplicity, and execution. I really appreciate this old bike. I'm irritated with myself for having to remount the battery vertically. That was a redundant 1 1/2 hours I didn't need. Oh well. Blazing a new trail here!
Indeed, you are blazing new trail! Thank you for taking us along with you. :)

Spud :)

[FastDoc]

I've ridden The Dirt Rat every day so far since it's been done. Another 20 miles after work today, and I'm taking it to the sand dune/desert area tomorrow.

Today I installed a choke cable (Thanks, Katoranger!) and a new(er) gas tank. I was going to change the fender and headlight surround but ran out of energy and ambition for today.

The new tank had a petcock leak, so I had to change it again to install the old petcock. Since that one did not like being removed I got to do the job a third time when it too leaked so I added an O ring to the petcock's aged gasket. No leaks but a 30 minute job took an hour and a half. :x

You ALL know how that goes, don't you? :roll:

[FastDoc]

Choke off:

http://img.photobucket.com/albums/v25/maule/DSC06384.jpg

Choke on:

http://img.photobucket.com/albums/v25/maule/DSC06385.jpg

Choke knob:

http://img.photobucket.com/albums/v25/maule/DSC06382.jpg

Old tank. Aweful:

http://img.photobucket.com/albums/v25/maule/DSC06378.jpg

http://img.photobucket.com/albums/v25/maule/DSC06377.jpg

New tank. Pretty nice!

http://img.photobucket.com/albums/v25/maule/DSC06381.jpg

The Dirt Rat in it's current state:

http://img.photobucket.com/albums/v25/maule/DSC06380.jpg

http://img.photobucket.com/albums/v25/maule/DSC06379.jpg

[Weldangrind]

I can work with that old tank. Please throw it on the pile. :D

[BillR]

Choke off:
Choke on:

Choke off:
Choke on:

Choke off:
Choke on:

Very good...Now you get to do the wax... :lol:
Sorry, couldn't resist.
Great job on getting the "Rat" going. I'm starting to get a bit psyched to have a go at my "Drowned Rat" Skorpion...
Bill R

[MICRider]

Dirt Rat is looking less ratty all the time... Shiny new motor, shiny tank. Love the pictures and happy that the bike turned out so well :D

[FastDoc]

Choke off:
Choke on:

Choke off:
Choke on:

Choke off:
Choke on:

Very good...Now you get to do the wax... :lol:
Sorry, couldn't resist.
Great job on getting the "Rat" going. I'm starting to get a bit psyched to have a go at my "Drowned Rat" Skorpion...
Bill R

To wax it first I'd have to wash it and have not even done that yet!

We'd love to follow along with the Drowned Rat Skorpian Rebuild!

[FastDoc]

I have the new front fender and fairing on The Dirt Rat. Still has not been bathed yet... :?


http://img.photobucket.com/albums/v25/maule/DSC06390.jpg

http://img.photobucket.com/albums/v25/maule/DSC06388.jpg

http://img.photobucket.com/albums/v25/maule/DSC06387.jpg

http://img.photobucket.com/albums/v25/maule/DSC06386.jpg

[SpudRider]

Wow! The new headlight and fender look great! :)

Spud :)

[MICRider]

Wow! The new headlight and fender look great! :)

Spud :)

X2, the new plastics look fantastic! Love the XR's, great bikes!

[FastDoc]

After I took these pics, I rode it 10 miles, let it cool and actually WASHED it! Some engine degreaser, S100, and judicious use of a power washer made a huge difference. :!:

I bought a can of Krylon Fusion in gloss white to do the side panels, maybe tomorrow. Getting there!

I know the can says no primer is necessary, but would it give me a better result? I was planning on experimenting on the backsides of the side panels and the rear fender which I'm replacing anyways, but wanted opinions. :D

[Jim]

Looking good... Did you choose white so you can show off the mud better? :D

[FastDoc]

Looking good... Did you choose white so you can show off the mud better? :D

I chose white because I already had a brand new Acerbis front fender and headlight fairing leftover for another project bike I finished and sold 2 years ago! :idea:

[Jim]

Oh well that is a great way to choose, sorry if you posted about that before, I kind of skimmed through for pictures :oops:

[SpudRider]

...I bought a can of Krylon Fusion in gloss white to do the side panels, maybe tomorrow. Getting there!

I know the can says no primer is necessary, but would it give me a better result? I was planning on experimenting on the backsides of the side panels and the rear fender which I'm replacing anyways, but wanted opinions. :D
By all means, test paint the back sides of the panels. ;) However, if you prepare the panels properly for painting, you won't need a primer. The Krylon Fusion spray paint acts as its own primer, and it does an excellent job! :)

Spud :)

[FastDoc]

I'm just wondering how well white Fusion will cover red plastic. Oh well, we'll know tomorrow!

[SpudRider]

I'm just wondering how well white Fusion will cover red plastic. Oh well, we'll know tomorrow!
I think your concern might be valid, Doc. ;) If the white, Krylon Fusion paint doesn't cover well, I have a solution. First spray some khaki, Krylon Fusion Camouflage paint as a base color. The khaki camouflage paint covers extremely well, and will provide a very nice base color for the Krylon Fusion, gloss white. ;)

Spud :)

[FastDoc]

I'm just wondering how well white Fusion will cover red plastic. Oh well, we'll know tomorrow!
I think your concern might be valid, Doc. ;) If the white, Krylon Fusion paint doesn't cover well, I have a solution. First spray some khaki, Krylon Fusion Camouflage paint as a base color. The khaki camouflage paint covers extremely well, and will provide a very nice base color for the Krylon Fusion, gloss white. ;)

Spud :)

Good to know, Spud.

BTW I went riding on the Columbia River today, check out the Ride Report section! :D

[Weldangrind]

We're going to need photos of the freshly bathed Dirt Rat.

The white looks really good. Son of Weldangrind has his eye on a spare white acerbis fender I have for my XR; maybe we'll make some changes after we learn about your rear fender experience.

BTW, I think that Krylon would hook better without a primer.

[FastDoc]

The paint on the side panels is drying. The Fusion worked well, once I got past the awkward pink phase!

We'll see how well it holds up although any scrapes or scratches can be very easily fixed.

I also repainted the kickstand. It had no paint left on it and was rusty. Next step is the exhaust.

Pics soon!

[FastDoc]

Hey I made some good progress today!

Side panels off, rear fender painted and mounted. The fender is cracked badly and will be replaced, I just wanted to see how it looked the right color and in place:

http://img.photobucket.com/albums/v25/maule/DSC06397.jpg

My shiny painted kickstand. Only a Chinarider would appreciate this!

http://img.photobucket.com/albums/v25/maule/DSC06413.jpg

The header drying on an XR100 drying rack 8) !

http://img.photobucket.com/albums/v25/maule/DSC06408.jpg

Muffler. Both were painted with Rustolem Flat Black BBQ paint:

http://img.photobucket.com/albums/v25/maule/DSC06407.jpg

Mounted again:

http://img.photobucket.com/albums/v25/maule/DSC06412.jpg

http://img.photobucket.com/albums/v25/maule/DSC06411.jpg

http://img.photobucket.com/albums/v25/maule/DSC06410.jpg

Panels painted and looking quite good!

http://img.photobucket.com/albums/v25/maule/DSC06409.jpg

The Dirt Rat getting spiffy!

http://img.photobucket.com/albums/v25/maule/DSC06414.jpg

http://img.photobucket.com/albums/v25/maule/DSC06415.jpg

http://img.photobucket.com/albums/v25/maule/DSC06416.jpg

Closeup of new engine and exhaust:

http://img.photobucket.com/albums/v25/maule/DSC06417.jpg

http://img.photobucket.com/albums/v25/maule/DSC06412.jpg

I did my painting in a heated shop seperate from the house.

Here's my YZ80, leftover from the Big D. It was my stepson's. They left it here when they blew town and I can't sell it as I don't have the title. Ugh. It was a fast and competitive racebike. I rebuilt it...

http://img.photobucket.com/albums/v25/maule/DSC06404.jpg

My friend Roger's kid's 2 XR100's. I fixed them up. They don't look nice but they are safe reliable and run great now that I went through them. Roger helped and learned a lot in the process. It was fun!

http://img.photobucket.com/albums/v25/maule/DSC06405.jpg

[FastDoc]

I will repaint the swingarm next week when I have the wheel off to replace the rear sprocket and drive bushings. I have new original looking swingarm decals also coming in the mail. I'm also waiting on a new blue seat cover.

Last step will be repainting or touching up the frame. I will NOT be removing the engine. I'm not going to push my luck!

[Jim]

Looks like some good progress :)

[SpudRider]

The bike looks great, Doc! :) Krylon Fusion spray paint is an excellent product. ;) I really like the red, white, and blue color scheme!

Spud :)

[Weldangrind]

Nice job Doc. 8)

Where did you get the swingarm decals? Where did you find the tank and shock? What about the new seat cover?

[FastDoc]

Here are the decals:

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=220547000328&viewitem=&sspagename=STRK%3AMEWNX%3AIT

The gas tank was from a guy in the XR forums at TT. $40! The shock was off eBay, $33 shipped. If you need a shock you can have my old one. It's a little soft, but the preload is all the way down, you can adjust that, as well as the compression and rebound, I think. Let me know. If you don't want it I'll eBay it.

[Weldangrind]

Thanks for the decal link. They're not exactly the same as the originals, but they look good. I'll let Son of Weldangrind choose.

Where did you buy your new seat cover?

Thanks for the offer of the shock. Ours is wasted, so yours might be better.

[FastDoc]

The shock is in your pile. :D

Here's the cover. The picture is a generic. The price was $30 OBO. I offered $20 and they took it. Nice people to work with, BTW.

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=190452316026&ssPageName=STRK:MEWNX:IT

[FastDoc]

New seat cover installed :D

Not a concours restoration but not bad. It couldn't be done smoother because the foam is not smooth. Indeed I left the old cover on and put this one on top to help it look better and maybe be stronger.

It took about 1/2 hour and a spring powered staple gun. :P

The plastic seat pan is degraded and actually broke in some places from the staples so I took it easy. :?

http://img.photobucket.com/albums/v25/maule/DSC06421.jpg

http://img.photobucket.com/albums/v25/maule/DSC06420.jpg

http://img.photobucket.com/albums/v25/maule/DSC06419.jpg

http://img.photobucket.com/albums/v25/maule/DSC06422.jpg

[katoranger]

Dirt Rat looks like a new bike. Just right restoration for the trails.

[FastDoc]

Tomorrow or Wednesday I'll do the rear sprocket and cush bushings and change the handgrips. While I have the real wheel off I'll paint the swingarm.

Then fork seals and repaint the frame (I really am not in the mood for that) and I'm done! :D

[FastDoc]

Here's the old seat cover. I think I did an OK improvement here:

http://img.photobucket.com/albums/v25/maule/DSC06332.jpg

http://img.photobucket.com/albums/v25/maule/DSC06335.jpg

http://img.photobucket.com/albums/v25/maule/DSC06334.jpg

http://img.photobucket.com/albums/v25/maule/DSC06333.jpg

[SpudRider]

You did a beautiful job, Doc. :D The Krylon Fusion paint job on the side panels and rear fender is superb! I love Krylon Fusion spray paint. ;)

Spud :)

[Weldangrind]

The seat looks really good; thanks for the eBay link. I'll look into buying a couple of different covers from them.

When you have the rear wheel apart for the cush bushings, etc., you might wish to consider new sealed bearings. They're cheap, and they'll eliminate wobble.

Son of Weldangrind is now convinced that his panels should be painted white with Krylon Fusion.

[FastDoc]

+1 on the Fusion. I used primer on the backsides but none on the front. The primer is not necessary, just like the directions say. I used steel wool and mineral spirits to prepare the material. We will see how well it holds up, but touchups will be easy. I am VERY satisfied with the company I bought the cover from.

[FastDoc]

I have the new sprocket mounted. I'll be sending back the bushings, the old ones looked fine after all. I painted the swingarm. When it's back together I'll share some pics. Just will have to wait for the new swingarm decals to make it look complete. :D

I have the fork seals. It remains to be seen if I'll have the ambition to install them tonight or not. :?

[FastDoc]

The swingarm has been painted and the new sprocket installed.

This went well.

http://img.photobucket.com/albums/v25/maule/DSC06424.jpg

http://img.photobucket.com/albums/v25/maule/DSC06423.jpg

http://img.photobucket.com/albums/v25/maule/DSC06425.jpg

Then I got over ambitious and decided to do the fork seals. I did the right leg 1st and the seal looked good, which is good because the seals Bike Bandit sent me are incorrect. I changed the ATF and put it back together.

The left leg was leaking a little. I did the old masking tape trick and serviced it also with fresh ATF. I'll order new seals to do in the future but this should take care of it hopefully for a while.

[FastDoc]

New chain should be here soon. I did the handgrips last night so except for painting the frame, should I choose to, I think I may be done? Could it be? :roll:

Come to think of it, looking at that last pic, the Old Dirt Rat ain't looking bad! :D

[AZ200cc]

She looks great Doc, Most would have trashed her....Real riders like You saved her. :D

[FastDoc]

Thanks, AZ 8)

Since she was free I thought I could fix it cost effectively. Time effective is a different story though. The good news is I like working on bikes, because I have A LOT of time in this one. I'd guess 40 hours if you include research... :cry:

[SpudRider]

The swingarm looks great; the entire bike looks great! :D I do have two questions. What is the "old masking tape trick" for the fork seals? What is the rusty piece of metal located behind the right snail adjuster? :?:

Spud :)

[FastDoc]

Thanks, Spud.

The tape trick:

Clean the slider tube and wrap one course of masking tape around it, then gently push the taped slider in and out through the fork seal. In many cases this will clean off the debris that's making the seal leak in the first place.

The rusty piece of metal (I guess I missed one... :roll: ) is a lever welded to the axle. I think you can hold on to it to keep the axle from turning while working the axle nut on the other side.

The Rat is definitly coming along.

I wish I could find a can of OEM color spray paint for the frame so I could touch it up and not have to repaint the entire frame.

[Weldangrind]

Time to repaint the frame. :D Would you change the colour to something closer to Honda red, or try and keep the burnt orange look? It seems to me that I found a tractor paint that was really close to the stock colour, but I can't recall what brand it was. Don't be shy about looking to Rustoleum as well.

That bike is looking really good. Instead of replacing the seals on those shocks, do you want the CR125 shocks I have? That would give you the opportunity to upgrade to a disc brake.

What did you use for swingarm paint?

[BrianW]

Looking fantastic, Doc. Glad to see you making such good progress on it!

[FastDoc]

Time to repaint the frame. :D Would you change the colour to something closer to Honda red, or try and keep the burnt orange look? It seems to me that I found a tractor paint that was really close to the stock colour, but I can't recall what brand it was. Don't be shy about looking to Rustoleum as well.

That bike is looking really good. Instead of replacing the seals on those shocks, do you want the CR125 shocks I have? That would give you the opportunity to upgrade to a disc brake.

What did you use for swingarm paint?

The shocks sound good, but I'd need a lot else I'm not in the mood to invest in for The Rat. Like the brake, wheel, speedo drive lever, master cylinder, caliper etc. The drum is almost good enough, I'm inclined to stick with it for now. Thanks for the offer, though. I bet it's a better shock, too.

The swingarm paint is a paint (I forgot the brand) designed for aluminum cars wheels. VERY tough, resistant to abrasion and chemicals, very easy to apply. Duplicolor medium silver, I think, IIRC. It's a perfect match for the swingarm, and I've also used it to repaint fork sliders with excellent effect. I had some leftover when I repainted the stock wheels on my Ford 1989 Probe GT. I NEVER should have sold that car, BTW :cry: .

IF I was to repaint the frame from scratch, I'd use this paint.

Also, I used Rustoleum Tractor Paint for the XR100 I restored a couple years ago. Good stuff, and not a bad match either. I figured paint tough enough for a tractor would be good for a dirt bike. :D

[Weldangrind]

If you change your mind, the wheel comes with it. You'd then be looking for a matched set that includes the master, lever and caliper.

[FastDoc]

If you change your mind, the wheel comes with it. You'd then be looking for a matched set that includes the master, lever and caliper.

I might go for it. It would keep me from having to true my wonky wheel.

[Weldangrind]

That presumes the wheel I have is any straighter. 8O I better check it.

I'd be happy to bring it when we finally pay a visit.

[FastDoc]

That presumes the wheel I have is any straighter. 8O I better check it.

I'd be happy to bring it when we finally pay a visit.

Thanks. What year CR125? I can ask the guys at TT if the forks will fit.

[SpudRider]

This project keeps getting better, and better! :D I certainly hope I don't get unintentionally unsubscribed from this thread again! Once again, thank you for documenting all your great work, and thank you for posting all the great photos, Brother Bill! :D

Spud :D

[MICRider]

Thanks for the masking tape tip Doc! I am so going to try that before I replace my fork seals on my KLR :D

Cheers,
Stew

[SpudRider]

Thanks for the masking tape tip Doc! I am so going to try that before I replace my fork seals on my KLR :D

Cheers,
Stew
Yes, thanks for the tip, Doc! :) I have employed a business card in a similar manner to remove dirt from the fork seals. Others have used either a strip of photographic film negative, or a strip from a goggle tear off. ;)

Spud :)

[FastDoc]

Same basic idea. I think the texture of the tape is an asset, like the holes in 35mm film were.

I wonder how long it will be before a guy says, '35mm film' and no one knows what he's talking about? :roll:

[FastDoc]

I trued the front wheel. Nothing to it. 5 minutes. Spud was right, just like a bicycle. No pics of this one. :D

[Weldangrind]

That presumes the wheel I have is any straighter. 8O I better check it.

I'd be happy to bring it when we finally pay a visit.

Thanks. What year CR125? I can ask the guys at TT if the forks will fit.

It's an '88. It won't fit as-is, because the stem is too long. The choices are to either fabricate a spacer or press in an XR200 spacer. Since I have plenty of XR200 junk here, I'd be happy to do that for you. :D The CR125 forks are considerably beefier, and the triples are a little wider. I have the axle and spacer that goes with the front wheel as well.

[FastDoc]

Thank's W&G. I'll let you know. I'd like the disk but I also like the speedometer/odometer!

[FastDoc]

I received the new swingarm decals (nice! :D ) and rear fender (also sweet) for The Dirt Rat today. I hope to get them installed tomorrow. At that point, except for repainting the frame, the restoration is as done as its gonna get. At least until I get Wayne's custom decals. THAT will be the touch! 8)

The Dirt Rat and I have plans to ride tomorrow and Sunday. Life is good.

[Weldangrind]

I was reviewing the eBay link you provided, and I'm surprised that the seat cover fit. The listing says '83-'84, but the actual model years ran '81-'83, '84-'85 and '86 on.

I found a listing for '81-'83, so I think we'll be safe.

Do you have photos of the new fender? Was it a bolt-in, or did you need to mod it?

[FastDoc]

The first cover did not fit. It was a 'climb the tank style'. I sent it back with pics of my seat and they sent me the one I have now, it fit great.

The fender was a bolt on operation, once I located the points to drill the 4 mounting holes. I have pics of it on one of my threads. I'll see if I can't find it for you.

[FastDoc]

http://img.photobucket.com/albums/v25/maule/2-26.jpg

[Weldangrind]

Thanks Doc.

I saw that photo previously, but I was hoping to see a photo of the fender before it was installed. Do you have a link?

[Weldangrind]

Can you tell me where you bought that rear fender from Doc?

[FastDoc]

I think Motorcycle Superstore or Rocky Mountain ATV. About $20 IIRC.

[Weldangrind]

Do you have a part number or manufacturers name?

[FastDoc]

Acerbis Universal rear fender.

This is the fender and where I bought it from. Good price. Fast shipping.

http://www.motosport.com/dirtbike/product/ACERBIS-UNIVERSAL-REAR-FENDER-WHITE/?id=121084&psreferrer=http%253A%252F%252Fwww.google.com%252Fs earch%253Fq%257Cequalto%257Cacerbis%2Buniversal%2B rear%2Bfender%257Camp%257Crls%257Cequalto%257Ccom. microsoft%253Aen-us%257Camp%257Cie%257Cequalto%257CUTF-8%257Camp%257Coe%257Cequalto%257CUTF-8%257Camp%257CstartIndex%257Cequalto%257C%257Camp% 257CstartPage%257Cequalto%257C1&CAWELAID=622781586&segment=badger

[Weldangrind]

Thanks Doc!

I'd like to learn from this process. What made you choose that one, and how did you know it would fit? I just compared it with the stock XR200R fender, and it's a bit shorter; do you think that would cause water to splash the stock airbox?

I'm drawing on your vast experience. :D

[FastDoc]

I bought it because I've used many Acerbis parts in the past and thought they were good. I also already had matching front fenders and headlight fairings so I thought it would be a good 'theme'.

I figured it would fit becaue the Honda XR is about the most common dirtbike in the world, so that would define universal. Plus the plastic will give quite a bit if the mounts are a little narrow or wide. Mine were narrow.

As far as the airbox I don't see it being an issue. Note that I did have to trim the forward inner edge a bit with a Dremel and cutoff wheel. This was for tire clearance. The tire on it now is a 110. 100 is stock and this sucker BARELY clears the swingarm, chain, exhaust, and seat. If you are running a stock size rear tire you ought to be good to go.

Finally, I bought it because it was cheap. I AM a Chinarider, after all!

[FastDoc]

Some vast experience. I built one. 8)

[Weldangrind]

I stuck a monster 130 rear tire on Son of Weldangrind's rim, but it remains to be seen whether or not it will fit. I only installed it because it was free; I'm a China Rider too. :lol: