Messages

1

Honda / Re: 1982 xr80 timing chain

« on: September 09, 2017, 02:15:16 pm »

have done a couple of these on 75s and 80s you can buy on ebay a correct length chain 25h x 88 links if you get one that is joined grind or if you have a chain breaker kit use that and remove a link than on ebay you can get a 25h pit bike chain link with clip to join it up again, piece of wire or long magnet to feed it thru the case all good

2

Honda / Re: Best way to make an XR200 a Mid Field Gun

« on: December 21, 2016, 09:28:07 pm »

Bruce, I'm so happy you shared this with us but it's a shame in a way because you lose the 'Sleeper' effect where all the ring dingers just scoff and take you for granted the first time you line up. Would have loved to see how many club members sell their bikes to get one of those awesome XR200 'toys' after getting smoked.

Tell us more about forks and triple clamps and the pro shock. Longer travel, beefier parts etc?

Love that you have done hydraulic brakes but I suspect that is one of those things where it was just 'because I can' and not because of a desperate need to improve the cable setup.
Not familiar with Viper rules. Does this mean 4 strokes up to 250 can run in like an Evo 125 class?

Thanks PBMGold
Love the older 4 strokes just more smoother to ride than the 2 strokes ,don't get me wrong am nearly finished restoring a DG 1982 YZ80 J which i will race in the minis in the viper meets and have a 1980 YZ100G i picked up off evilbay for nicks and am making a IT175 barrel and DG head fit the cases a bit of welding and machining but it will bolt up  should be a interesting combo if i can get it to work also made a Vforce 3  reed and later flatside caby to fit the intake
getting back to the XR200 OzVMX member Wasp from SA made the rear shock for me using the old shock for dimensions but adding a extra 1" of length ,adjustable spring preload, adjustable dampening, twin adjustments on the reservoir for low and high speed rebound ,then a bit of mucking around mounting the reservoir and getting the right length and angle on the fittings for the hose before we could charge the shock with oil ect
the front forks i stripped down and got a company in melbourne to make me new sealing rings on the tubes and i machined up a set of emulators i had by tuning down the OD so they slide into the fork tubes then machining the dampening rod so the emulator sits correctly then sent them back to Wasp to set up the springs and preload
finally i drilled and tapped the fork caps so i could fit a set of air cell fork control chambers also had to make a set of brackets for mounting the chambers
the triple clamps are STD but polished and new allen key type bolts
also rebushed the rear shock pivot with heaver duty bearings and bushes
and your right about the hydraulic rear brake thought to myself why try to fix up old set up and get new cable when i can do something which looks a bit more trick
would love to run in the 125cc class but if have to run in 250cc class all good as im to old [pushing 60]to go hard 100%
last season raced a modded XR100 in the mini class against all the YZs and KXs hole shotted into the first corner a from the gate once, the bike is just as quick as the 2 strokes but not interested in pushing it hard in and out of the corners like the younger blokes so they end up passing me im in it for the fun

3

Honda / Re: Best way to make an XR200 a Mid Field Gun

« on: December 20, 2016, 08:29:39 pm »

Bruce, That is a beautiful piece of kit and sounds awesome although I hope it doesn't exceed noise restrictions. Can you advise more details. The forks look like they have thicker stanchions and did I spy a hydraulic line to the rear brake?

Do you reckon that it will be competitive against 250 2 strokes?

I just love it. Please add pictures, thanks.

Hi PBMGold
Maybe with a good rider on it, but with me on it i will give the 125s a run for there money
even though the seat cover says 250cc its only a first oversize 200cc on the bore and std stroke
yes rear hydraulic drum brake home made set up ,the exhaust has the baffle removed its alot quieter with it in
I actually have pulled down the engine over xmas as i was not happy with the way honda secure the main bearings in the cases from standard when i first assembled I was abit unsure , as the ignition side of the case only has about 2/3rds of lip to stop the crank from floating
seeing this engine has the a rev limiter set at 13,000 rpm around 11,000 it had a bit of a vibration when i was riding it and tuning it
so stripped it down and realized the higher rpm was causing the crank bearings to turn in the cases as the way honda locates each bearing does not have a lot of material there
so did some measurements and have machined the inside of the cases to accept a circlip type bearing and removed the crank bearings and cut a circlip groove in them
with the cases bolted together there is a .005 crush on the circlip to case this should fix the loose bearing problem
also static balanced the crank using some mallory metal going back to gether over the new year
the rest of the engine has had heaps of mods
duel map digital crank triggered inner rotor ignition, .0435" lift roller cam,14:1 comp forged piston ,bigger inlet valve shortened brass guides and flow ported head, 32mm flat slide carby, barnett kevlar clutch,mega lightened crank took heaps of material off the sucker, home made 40mm exhaust and reverse cone exhaust, reworked the oiling system to supply straight to the cam and added a oil cooler
really looking forward to racing it next season
will post some photos of it when i put it back together

4

Honda / Re: Best way to make an XR200 a Mid Field Gun

« on: December 20, 2016, 07:51:18 pm »

Hi Evo550
yes hydraulic rear drum brake just love tinkering with these old bikes the original cable missing and mount broken off the old frame so i thought up the hydraulic idea using a clutch master cylinder off a pit bike for the drum brake end, hand made all the bits works a treat but not race tested yet

5

Honda / Re: Best way to make an XR200 a Mid Field Gun

« on: December 19, 2016, 10:17:11 pm »

Hi Brains Trust. I've always had a thing for the little XR200. Really sweet bike but everything is a little kiddie built - skinny forks, mild motor. I wonder if anyone has done or considered fitting an XR200 motor into either a CR125 or CR80 frame. My goal is to build something with better suspension, about the same weight or lighter and a wee bit more power than my KLX 250. It would be used for Vinduro and Evo class VMX so the frame would have to be a twin shocker.

Does anyone have any of the components to suit, eg 200cc motor or CR rolling frame? Thanks.

Hi PBMGold
her is some food for thought my 1983 XR200 ive prepped for the Viper series 2017
front forks have emulators and set up by wasp in SA
he also fabricated the rear shock
engine mods are  all my work as im a engine builder by trade
home made reverse cone exhaust
looking forward to racing it against the 2 smokers
heres a vid of it when i was setting ignition timming and carby jetting

https://youtu.be/msbxIcnqvgM

6

Tech Talk / 1980 YZ100G with IT175 barrel and DG head

« on: December 04, 2016, 12:54:50 pm »

Need a little help here fellows
have acquired a complete 1980 YZ100g off evil bay for 200.00 a while ago
is complete but poor condition and not running
have done a little research on fitting a IT175 barrel and a DG head that i have
seems to me it will fit as the base gaskets are the same and the stroke is the same
head studs and heads are different but that doesn't matter as i have the matching DG head for the 175
the exhaust port is in the same position so i think the exhaust should match up

my questions are which is the best piston to use a YZ type one with or without windows in the skirt?
want to use it for motocross so the barrel will be going to Dave at 2 stroke performance for some extra porting
not sure if the skirts are for low down enduro type work ?

has any body on the forum done this type of combo any input would be appreciated
thanks
Bruce

7

Wanted / Re: YZ80 DG swing arm

« on: September 26, 2016, 06:36:10 pm »

thanks for the input love this forum its a wealth of knowledge and helpful people thanks again
spoke to Marco he is a bit snowed under with work ,damm it may have sourced one from the USA
as for the billet clutch i used a later model billet basket {Mitaka} which has provision for a extra plate  champered the ends to clear the cover and used Barnett Kevlar plates hand made the barnett cover using a old broken cover off a bigger YZ
here is some pics
http://s300.photobucket.com/user/logistics835/media/yz02_zpsgk2nhkoj.jpg.html
http://s300.photobucket.com/user/logistics835/media/prox%20basket_zps5ey7pvgt.jpg.html
http://s300.photobucket.com/user/logistics835/media/old%20basket%201_zps6erdh1d1.jpg.html
http://s300.photobucket.com/user/logistics835/media/Picture%20004_zpscctekff4.jpg.html

quote author=rocketfrog link=topic=40887.msg391032#msg391032 date=1472770504]
Marco could definitely do the job if you have a pattern for him. I have a DG arm for the YZ80E and the differences are subtle through the years. Early arms had a single strut between the upper and lower attachments, later models have twin struts and some of the last ones have extra gusseting as well as twin struts.

DG basically modelled the swinger off the OEM part but usually lengthened the arm and of course fabricated out of Al  Alloy and anodised Gold for that signature DG Trick appearance.

If you can live with a very good replica, contact Marco (Allyfab) and discuss your requirements with the man.

How did you go fitting the Billet Clutch Basket?
[/quote]

8

Honda / Re: Open Class XR race development and advise

« on: September 26, 2016, 06:01:15 pm »

Hey Mick
thought you would like to hear the XR200 going
Heres a short vid of it after setting the timing and carby jetting with a 4 gas analyzer still a bit more finer tuning and riding, thats what XRs sound like with plenty of lightened and balanced parts nice and narly
pause the vid at the start and let it load then play otherwise a bit jumpy

http://s300.photobucket.com/user/logistics835/media/xr200%20tuning%20with%204%20gas%20analizer_zpskwyghyqy.mp4.html

Convicted to this idea. getting excited
Some bits and pieces starting to turn up I realise it is going to cost a Zillion x 3  arrh well, as I can patiently afford
Every single thing is readily available, bar nothing

A favourite movie was "On Any Sunday".
 One natural approach that has followed me since is the "Mert Lawwill approach"
Can always see him as plain as day grinding down that Harley cam follower to a "bare minimum" 
"light weight, works great" has stuck with me for life

Probably not so much on the 86 XR600 adv/tourer, more concerned with purpose.

But as for the VMX Moto X and Dirt tracker, I will definitely be going "Mert" all over their arses.
   
Desperate need to commision my new Lathe and Mill. That's going to be fun excited as.

I have already removed 8.5 kilos from the equation. by diet, exercise, training etc and these racers will be loosing a hell of a lot more than that

Stay tunned

9

Wanted / YZ80 DG swing arm

« on: August 20, 2016, 12:14:25 pm »

Bit of a rare item, looking for a 1982 YZ80 DG alloy swing arm
the only missing part for my DG themed YZ80 im restoring for the Viper mini class
any body know of or can point me in the right direction of one would be appreciated
been looking here and O/S for a while with no luck
thanks in advance

10

Wanted / Re: V force reeds

« on: August 20, 2016, 10:56:32 am »

Thanks Bruce that's kind of you.
I don't have an old number , It is for a Husky 420. At the moment all I have is a blank cylinder.

Hi Slakewell
Im going up to the Mototassani warehouse next week to look at some reed sizes
if your up for it draw a pic of your reed base gasket ,outside shape, inside shape, and hole spacing in mm
and i will see if we can match one up for you
cheers

11

Wanted / Re: V force reeds

« on: August 01, 2016, 10:46:36 pm »

V force melbourne distributor warehouse is a couple of doors up from my factory in tullamarine melbourne
I know the dude in the office have got reeds off him before, if you give me the V force # off your reed you have, i recon i can get one for you if you cant get else where
cheers

12

General Discussion / Re: Tools, I just put it down & now farrrk

« on: August 01, 2016, 12:50:10 am »

over the years i've worked out that is wasn't me loosing the tools
it was me forgetting who i lent them to and that same person not bothering or forgetting to return the borrowed tool
my solution to the missing tool problem is when my mates want to borrow a tool i now take a snapshot of them with the tool in there hands on my phone
works wonders if i cant find what im looking for in the shop I check my photos on my phone and bingo ! that jogs the memory of the missing tool
next problem is getting the mate to return it

13

Honda / Re: Open Class XR race development and advise

« on: July 02, 2016, 03:58:53 pm »

That's a great looking build Bruce G. Amazing, well imagined and expedited



[/quote]
thanks Mick, much appreciated
got 2 of these XRs as basket cases for nothing so thought i would resto one for the viper series
been building engines for many years as i am a auto machinest by trade did some home work on the XR engine and have overcome what i think are its weaknesses
got rid of the massive flywheel and cam trigger cdi to run a inner rotor ignition off the crank
lightened the hell out of the crank and then spent a lot of time balancing it with the rod and piston
bigger barnett clutch set up
re-routed the oil supply thru a cooler and straight to the cam
modified the oil pump flow rate
running a roller cam instead of pissy original one
slightly modified the weak chain tension er set up
running a 32mm flat slide
hooked up to a port flowed head running a 1mm bigger inlet valve
hand made the exhaust myself with a bigger o/d and reverse cone
have had it running but not tuned yet
it sounds like a wrf yamaha, revs very quick
the duel map ignition has the limiter set at 11000 rpm
tuning it with Sunco C14 its a leaded fuel much easier to tune than unleaded crap
Wasp from this forum made the rear shock from scrap for me with all the late model adjustments
I fabricated a set of race tech emulators to fit the inner tubes then got Wasp to set up the springs
so with a bit of luck it should handle good
chomping at the bit to ride it

14

Honda / Re: Open Class XR race development and advise

« on: July 01, 2016, 12:55:03 am »

Hey Mick
XRs only did the big fin head on my xr200 for me a couple of years ago you can see it in the pics
spent a lot of time looking for XR race bits for my 200 2 valve
also got mega cycle cams to do a roller cam for it
so with a oil cooler and bigger fin head to keep it from over heating and the roller cam and a rerouted oil supply to the head direct
this Xr should hold together also running a beefier barnett clutch and a selectra inner rotor duel map digital ignition i made to trigger of the crank
so no massive flywheel now

15

Honda / Re: Open Class XR race development and advise

« on: June 29, 2016, 10:28:53 pm »

http://s300.photobucket.com/user/logistics835/media/xr200%202_zpstykrvwsc.jpg.html
http://s300.photobucket.com/user/logistics835/media/xr200%201_zpswv4gstgl.jpg.html
Here is a couple of photos of my xr200 nearly ready for racing
XR class would be good
will be running it the Viper series against all the 250 2 strokes
and the over 45s old man events