XR200 top end rebuild: honing cylinder, lapping valves, new rings, cam chain and assembly

Enough parts came in and I was able to get the engine back together. Still waiting on a couple carb parts but it’s pretty much ready to go back in the bike!

[@johndimeo1821]

I watch these rebuilds all the time. Never know if you will see something interesting. I have used a couple of pieces of wood to hold the piston up high and stable while trying to fit the cylinder.

[@Garage2Trail]

That’s a good idea! I’ll have to remember that next time, thank you!

[@Gino-jf6gc]

You done an excellent job honing that cylinder!!

[@Garage2Trail]

Thank you sir!

[@andyshondaxlsrestorations4733]

Great vid m8 it's nice when you can get oem parts for the job 👍

[@Garage2Trail]

Thanks Andy! You can never go wrong with OEM!

[@wattie1050]

Great top end rebuild , be good to hear it run after this . I remember doing the valve lapping on my old xl 250 years ago , quite awkward to get the wee collets on the springs .Good job .👍

[@Garage2Trail]

Thank you! It was a little tricky but not as bad as I thought it would be.

[@kentkieffer7533]

You did a perfect job😀

[@Garage2Trail]

Thank you Kent, I appreciate the feedback!

[@martintelford8763]

Nice work on the build. I'm almost finished rebuilding a 1987 XR200R, just some carb tuning remaining. Don't forget to set the firing timing (the second line on the flywheel) with the position of the CDI, but maybe you plan to do that once you get the motor in the bike. Anyway, I look forward to seeing the next video.

[@Garage2Trail]

Thank you! I actually do need to do that yet. I had to piece the CDI stuff on just to wrap up the video because I’m still waiting on a couple gaskets for it that got lost in the mail 😡. Didn’t want to delay the video any longer than it already was. I appreciate the heads up!

[@snorkelmancraig2740]

thanks

[@snorkelmancraig2740]

thanks man

[@frankdillon6127]

on my 74 xl-250 i had to remove tension on the rear cam chain plastic tensioner to allow the chain to slide over the sprocket.

[@user-fz4xn8ch6c]

👍

[@frankdillon6127]

another way is put water into head over the valves and blow air into the ports and watch for air bubbles.

[@Garage2Trail]

Good idea, thank you! I’ll have to remember that for next time.

[@chrispageXR200r]

Great job on the rebuild, I noticed you had a manual off to the side of your workbench where did you get it like to know thanks

[@Garage2Trail]

Got it on eBay. Here’s the link. The factory Honda workshop manuals are ridiculously priced. www.ebay.com/itm/265337507604?mkcid=16&mkevt=1&mkrid=711-127632-2357-0&ssspo=VOMvm8qcQXO&sssrc=4429486&ssuid=1QWenE7CT8u&var=&widget_ver=artemis&media=COPY

[@andrescheuer4400]

I was still a kid and thought gasket maker was king yep fried a XR head no oil up there

[@jeschreindl]

Ah man im at work i cant watch right now 😂

[@giveitstick66]

hi, i'm busy with an '82 restore so your video is a tremendous help, thanks. One question.. at 34.07 on your video there is a shot of the top and on the left of the shot is a small hole? in the body of the cover opposite the end of the cam, i've read somewhere that there is a small rubber stopper type part that goes in there..? can anyone clarify this..? mine didn't have one when i opened it up so had to order one.. cheers

[@Garage2Trail]

Glad the video is helping out! There is a little rubber bung that sits down in there. I can’t recall at the moment what that’s for but there should be be one there in that spot.

[@csedan510]

I was waiting to see you check the CDI timing/alignment.

[@Garage2Trail]

I think I marked the position before removing it. It’s been over a year since I worked on this one 😃

[@csedan510]

@@Garage2Trail Thanks for the reply. Even with the pickup clocked all of the way to the right I can’t get it to align with the advance unit. TDC been checked 3 times, I can’t figure it out. I even moved the cam gear a tooth each way but “T” would not align with cam gear mark.

[@Garage2Trail]

@@csedan510 hmm, I wonder if your advance unit is out of another 200 motor weather it be the ATC model or perhaps a different year XR200 that may have been different. I can’t say I’ve done enough to know for sure. I recently picked up an ‘83 XR200R so I’ll probably be getting into this again.

[@csedan510]

@@Garage2Trail it was working and oriented properly when I took it apart or so says the old screw marks on the base plate. I’m got to check flywheel and make sure key isn’t broken.

[@Garage2Trail]

Ahh ok gotcha. Not a bad idea to look at the key…maybe it got crunched when you to tightened down the flywheel.

[@Eastontheman]

Rebuilding this same motor right now. What was the spec you torqued the 4 main top nuts to? Great video!

[@Garage2Trail]

Thank you! Let me check the manual when I get home later on. I’ll let you know.

[@Eastontheman]

@@Garage2Trail great thanks

[@Garage2Trail]

@@Eastontheman looks like the cap nuts are torqued to 21ft-lbs or 28N-m

[@andrewYdoesntAnyHandleWork]

Hey there just wondering where did you get all the parts for the bike, really helpful video thx!

[@Garage2Trail]

Thanks! I got most of it off rockymountainatvmc.com. Check the OEM parts section.

[@andrewYdoesntAnyHandleWork]

Oh and one more question, any chance you could give me a link to the feeler gauge you used? Thx!

[@Garage2Trail]

@andrewYdoesntAnyHandleWork the feeler gauges I use are old Craftsman’s that my dad gave me…sorry I don’t have a link to those lol. I’m sure any on Amazon with good reviews would work though.

[@andrewYdoesntAnyHandleWork]

Hey good morning, what is the torque spec for the top nuts?

[@Garage2Trail]

@@andrewYdoesntAnyHandleWork hi Andrew! The book I have shows 20-22 ft. lb.(240-264 in. lb) on the accorn nuts, and 6-9 ft lb(72-108 in. lb) on the allen bolts

[@DC-sh8mr]

Pour alcohol or thinner down to check valve seats. It shows better.

[@Garage2Trail]

I’ll have to remember that for next time, thank you for the tip!

[@user-uh3tf1il2q]

Have question i bought a roller,1998 xr 200 r honda the bottom end is good it moves,but it didn't come with a piston,so i ordered piston kit on ebay brand new ,but the connecting rod thatbwas left in there is not pushing the piston up far enough,what to do,NOTE : THE KIT I ORDERD WAS BIGGER 250,. SO DO I NEED GET ANOTHER CONNECTING ROD AND IF I DO TJAT WILL I HAVE TO CHANGE THE CRANK ALSO? HOPE TO HER FROM YOU?

[@Garage2Trail]

Was it a “big bore” kit specific for the XR200? Its tough to give a definitive answer when there are mix matched parts unfortunately. I’d hate to give you bad info and have it cause damage to your bike.

[@user-uh3tf1il2q]

@@Garage2Trail yes it was a piston kit from eBay that was bumped up to a 250 cc which is what 66.5?

[@Garage2Trail]

Not sure…everything I’ve rebuilt has been back to stock specs so I probably won’t be much help. Sorry! I’m always worried about aftermarket stuff fitting correctly. Does the kit mention anything about a connecting rod? Maybe it was for the CRF230? Just a guess tho

[@user-uh3tf1il2q]

@@Garage2Trail no it didn't say nothing about that ,but could you send me the actual size of the original poison for the Honda XR 200 r, like 66.50 or whatever it is called? Maybe if I get that I can move forward

[@johnmathewson985]

any alignment for the CDI ? I marked my backing plate and case to make sure timed properly.

[@Garage2Trail]

I also marked mine but if I recall correctly, it only went back on one way.

[@johnmathewson985]

@@Garage2Trail the backing plate can be rotated, held in place by 2 phillip head screws.

[@Garage2Trail]

@@johnmathewson985 ok yeah, I marked mine but let me check the manual to see if they make note of any factory timing marks. When I got it back together, it ran perfect so I didn’t change anything. I’ll get back at ya…

[@Garage2Trail]

Ok looking at the manual, it says to set the timing marks on the flywheel to “F” with the index marker on the top of the hole on the side cover. Then install the base plate aligning the index mark on the pulse coil (small black box that has the shielded wire coming out) with the mark on the rotor. Basically two vertical lines….so I guess really you need to make sure you got that rotor on the right way while at “F” on the flywheel before worrying about the baseplate. Hope that helps. Kinda hard without pictures to explain.

[@johnmathewson985]

@@Garage2Trail thanks, you when above and beyond. This will help anyone who did not mark the plate first.

[@andrewcapra52]

Can you give me a link for the Flex Hone that you used?

[@Garage2Trail]

Flex-Hone Cylinder Ball-Hone 65-67mm for Honda XR200 1980-1984 a.co/d/1UN4cvy

[@snorkelmancraig2740]

wht was the lapping compound called need to do my xr200 81 and oils to use to do top end

[@Garage2Trail]

I’ll check on that for you and let you know…not home at the moment.

[@Garage2Trail]

I used Permatex Valve grinding compound 80037

[@snorkelmancraig2740]

bey g2t can u please find out wht size of bolt or wht tool to get the flywheel off to get to back of timung chain stuff ahhhh

[@Garage2Trail]

Believe it or not, but the rear axle bolt is what I used. The threads are the same. Just make sure they are cleaned up and good before cranking down into the flywheel so you don’t booger those up.

[@snorkelmancraig2740]

no way u kidding me iv been blowing my mond on trying to figure it out and its right infront of me man 😮😮😮😮😮😂😂😂😂

[@Garage2Trail]

@@snorkelmancraig2740 lol…I didn’t know until I saw someone mention it on a Facebook XR page. mine is a 2002 but I think the axle is the same on a lot of years.

[@snorkelmancraig2740]

well worth a shot ill be glad to let u know going to tey it now mines a 81 xr 200 hear we goo

[@snorkelmancraig2740]

it screws right on how much frce should i use i am aply alot of presser un not moving should i keep going

[@BLUESBOYBENFIELD]

Looks like the cam follower ends of the rocker arms were a bit worn……..

[@Garage2Trail]

I wonder if that’s attributing to the little bit of noise I hear just above idle. It goes away when the revs climb and you only hear it for a second when the rpm drops down. When it hits idle speed again you don’t hear it. I’ve double checked the cam chain tension because that was my first thought as it sounded a bit like chain rattle but that’s tight. I adjusted the valves too and they are spot on. Bike starts easy hot and cold and doesn’t smoke so I haven’t been worrying too much about it. Been riding it a lot too.

[@snorkelmancraig2740]

and when I check my values it will be to dead center for bothe values

[@Garage2Trail]

It will need to be at TDC while both valves are closed

[@user-ss2rk9xg7f]

43:41 whats that thing called with the springs on it need the name for my one

[@Garage2Trail]

That’s the timing advance mechanism

[@user-ss2rk9xg7f]

@@Garage2Trail thanks man

[@user-ss2rk9xg7f]

@@Garage2Trail thanks for all the content to keep it up🤙🏼

[@Garage2Trail]

@@user-ss2rk9xg7f not a problem, glad to help! Thanks for tuning in as well!

[@mitchfretz7588]

Hey which site you getting oem parts from?

[@Garage2Trail]

Rockymountainatvmc.com. They have an OEM section and most of it’s in stock.

[@mitchfretz7588]

@@Garage2Trail rebuilding my 88' XR200 bent intake valve as well, Chinese valve didn't fit 🙄

[@Garage2Trail]

@@mitchfretz7588 oh man that sucks. OEM will treat you right.

[@micahdyck7932]

39:38 for my future reference lol.

[@Garage2Trail]

Rebuilding a 200 as well?

[@micahdyck7932]

@@Garage2Trail changing my cam chain slack at the moment, oil filter etc. but not a xr200 it’s a cxr200 😂 its a 86cr with a xr200 in it. But I’ve used this vid for valve lash as well.

[@Garage2Trail]

@micahdyck7932 nice! My friend bought an 82 CR125 roller to put an XR200 motor in it!

[@Troyth3boy]

What size flex hone?

[@Garage2Trail]

www.amazon.com/dp/B079RMKPKK?ref_=cm_sw_r_apin_dp_R2AJMHA9BYZB4VS0CRTT

[@Troyth3boy]

It's unavailable

[@Garage2Trail]

Ahh damn, that was back in March I got that. Try googling that size…might be able to find it from another vendor.

[@Garage2Trail]

I just checked the link again and it said they are available. Maybe it just got restocked.

[@snorkelmancraig2740]

i own 2 81 xr200 and doing the same thing not for vid id be shit out luckcheers buddy

[@Garage2Trail]

Cheers! Glad the video helped out

[@snorkelmancraig2740]

@@Garage2Trail could u tell me wht grease u were useing when u asemmbled the top end and to lube stuff with please

[@Garage2Trail]

@@snorkelmancraig2740 for the valve cover I just used some permatex black gasket maker. For the moving bits you’ll want to use assembly lube or just liberal amounts of oil