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About Rooney140

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  1. Rooney140

    fork bushings '84-'85 XR250 KYB 38mm (modified XR 200)

    Check with Racetech. I did a quick application lookup for an 84 XR250R and they list both inner and outer bushings and some other parts. http://racetech.com/ProductSearch/1/Honda/XR250R/1984
  2. Rooney140

    2001 XR200 Lighting Project

    Please excuse me if I am missing something, but have you grounded one of the jumped wires and checked voltage on the other? The newer XR200R alternator needs to be grounded to provide AC for lights. If you are using the OEM regulator from the lighting kit, it does the job of grounding, otherwise read on. I have a fully functioning ac/dc system on my 98, designed with the original intention of just installing lights but could be street legal, at least in MI if needed. I started with the common Honda 4 wire regulator / rectifier as found on many smaller bikes and scooters with batteries. These are also used on many of the imported ATV's with clone engines. Your reg/rect should work for the application if it is functioning properly. I removed the XR200R jumper and grounded the pink wire, keeping with OEM colors I connected the yellow wire the the reg/rect input. After grounding the reg/rect you are left two open terminals, 12v dc (probably red) and regulated 12v ac. You can design your harness from there. I used a universal left combo switch with headlight, turn signals and horn and wired it in appropriately. My generic XR type headlight with hi/lo uses AC and is only on when engine is running. After sizing a small 1.2A 12V battery in the airbox I ran a Maier XR tail/stop light and horn off of DC. I also fitted a Honda type key switch from an imported ATV which kills the engine and DC when off. I have had no problems keeping the battery charged with normal riding, the 35w headlight is bright enough and the horn is loud even with the engine off. LED's would reduce the power consumption of the 1157 rear bulb if needed. Turn signals are not required here but I have the option later.
  3. Rooney140

    New build and Wiseco headgasket leaking issue

    I had the same issue a few years ago with a Vesrah gasket. After the first hard ride noticed a little oil around the left side of the jug where the head meets, really just enough to attract dust and dirt. Finished that season and over the next winter I took the advice of others and installed the updated Honda gasket, no more problems. Recently sold that bike after 1000 miles of street / dirt use, but if I rebuild another I will install the OEM gasket from the start.
  4. Rooney140

    1983 XL200R FMF or Other Slip On Muffler?

    Congrats on the purchase, these are cool bikes. I have done a lot to mine and overall the bike works pretty darn good the way it came from the factory. I have an aluminum Cobra slip on on my 83 XL, it is a specific application to the 83/84 XL200R and required a reducer at the inlet to fit the stock headpipe. I have not seen it listed in a catalog since the 90's but a few have popped up on eBay over the years. I think Cobra got out of the dirt bike exhaust game a while ago. It is a nice silencer, lighter than stock, has a spark arrestor and nice sound but is a little loud. It fits pretty good but melted a bit of the super rare right side panel plastic on mine and the power gain is negligible even with other mods. I also have an old Supertrapp aluminum slip on designed for the 81-83XR200R, it has similar mounts but I think it is longer and I have never actually tried to fit it on a bike. Anything is possible with some ingenuity. I will say neither exhaust will fit my 98 XR200R without mods, so the chances of the FMF designed for the newer bikes fitting are slim. Mine will be for sale soon, but will come attached to the bike and all of the spares I have amassed over the years. FYI the bike is a very close brother to the XL125R sold in Europe for a few years after 84.
  5. Rooney140

    Ultrasonic Carburetor Cleaning........?

    If you are asking for opinions I'll offer mine. I have used an ultrasonic cleaner to clean carburetors and they work. I have a large and a small unit from Harbor Freight and use them for cleaning many things. I have not noticed any ill effects from the ultrasonic cleaning in the ten or so carburetors that I have cleaned. My preferred method of cleaning a carburetor is with a proven aerosol cleaner, shop air, and maybe a soft copper wire for cleaning stubborn passages. There are big differences in aerosol cleaners, experiment and find one that works. I have cleaned a carb the old way and thought it was spotless, then put it in the ultrasonic only to find more debris and grit on the bottom of the tank. This might be residual dirt from the exterior carb body or from inside of the metered orifices, I don't know but its there. Ultrasonic does not remove the gelatinous ooze that ethanol and water can create, but most carb cleaners won't dissolve this either. Brass jets will come out shiny and looking new, in 20 years of working on bikes I have yet to find a worn out main or pilot jet. Warm water and dish soap or simple green work great in the machine. The ultrasonics do take time to work, multiple cycles are necessary as well as a good drying via air compressor. I consider the larger unit a good purchase, it has a heater and was probably less than $50 on sale a few years ago and can be used for other things. There are some other more expensive options out there too.
  6. Rooney140


    That engine # HEO3E-6134345 shows as being from a 1997. I am not familiar enough with the different years of 80/100s to know any differences in frames or engine mounts but thought knowing the engine year would help.
  7. Rooney140

    XR confusion

    The leakdown tester is a great tool and will help pinpoint any areas of compression loss and is a good indication of overall top end health. The "decompression" system should not affect a compression test if it is adjusted properly. When conducting the leakdown test, set the engine to TDC by turning the flywheel nut rather than the kickstart to avoid engaging the compression release.
  8. Rooney140

    84 XL 200 engine swap and the basics

    There is a difference in countershaft lengths in later engines that could result in the sprockets not aligning. I am not 100%, but I believe it is after 86. Hooper Imports was a source for chinese engines, they had a special sprocket designed to accomodate the different countershaft lengths in different chassis. I have a 1980 XR200 engine in my XL200R, no fitment issues, but plan on using the XL electrics, especially if you plan on keeping the lights. The XL has a 24mm carburetor opposed too most other 200's with a 26mm, use the original if you plan on keeping the stock airbox. The six speed XR engine is an improvement off road compared to the five speed XL. These engines are not that complicated, start searching microfiche online to see if you have all or at least most of the parts to your current basketcase. If you have most of the parts, buy a good manual and replace what is worn or damaged, should be cheaper than buying a used engine which you will have no history on.
  9. Rooney140

    DR350S Dies after closing throttle

    I have had similar issues with my 350se with the stock carb. Ran great but would die randomly, also had issues with a slow visible bowl leak. Does your local gasoline have ethanol mixed in? Is the gas more than a month or two old? When your bike quits, turn the petcock to prime and crack the bowl drain as soon as possible to see if it is starving for fuel. On my bike gas flowed freely from the fuel line, and appeared to flow fine from the bowl drain but would slow and eventually stop after about 15 seconds. All vents were clear. Ultimately I discovered a decent amount of ethanol induced goo in the carburetor body between the fuel inlet and the float needle. Even with the 90% blockage the bike would start and run at low speeds, but would die out after a high speed run. After sitting a minute or two the bowl would refill and the bike would run again. Carb cleaner would not disolve the goo but compressed air blew it out. We have had E-10 gas here for a while and I see issues more and more. The ethanol absorbs moisture and eventually falls out of solution with the gasoline, there are tons of articles on the internet about it. After a tank flush I finished the carb off with a new bowl gasket, float needle and seat and related o-rings to cure the seeping. I got a kit on an auction site for less than $20. I now use an ethanol treatment and haven't had anymore issues.
  10. Rooney140

    2002 xr80r ... But what year is my engine?

    My Redbook only goes to 98, but I would guess that it is original. 1993-1997 engine #'s start HE01E-6200001, 1998 #'s are HE01E-6300001. Assuming continuation of sequential numbering, your engine is post-98, maybe someone else has newer production info to pin down an exact year.
  11. Rooney140

    stumped please help

    If you decide to replace the choke, I found that on my 95 DR350SE that the plastic nut that screws into the carb had cracked. This is under the rubber boot. My choke would not stay "on" or out without holding it. Not sure if this was a vacuum leak, but the choke was a hassle to use. I purchased a new choke assembly on eBay for a tm33 pumper carb. The choke shaft for the TM is shorter but will work on the BST carb, the knob will be a little harder to reach. In the end I disassembled the new and old choke assemblies (with a little persuasion) and used the original BST shaft with the nut and boot from the new TM assembly. Now my choke functions properly The tm33 choke is about $13 on eBay, cheaper than the $30+ for OEM.
  12. Rooney140

    xr200 replacing guide valve ?

    The guides are pressed in and require reaming after installation. The valve seals are easy after removing the springs, but that will require a compressor or some ingenuity. A reamer is about $50 if you can press a new guide in yourself. A new guide will probably need a new valve and a new valve will need a freshened seat, a Neway valve seat cutter is $150-200. If you plan on doing this job on multiple bikes like I have, the investment is worth it, otherwise take it to the shop.
  13. Rooney140

    Rear spockets?

    Sprocket Specialists lists aluminum rear sprockets available for 81-83 XR200R in 28t-74t. They might have a option for a larger front sprocket as well.
  14. Rooney140

    Exhaust studs

    6x32 is the length of the original stud. Should be 6mm x 1.0 pitch x 32mm long. Pretty sure if you tried to chase the threads with a 6-32 tap you would be surprised to find the diameter quite a bit smaller than the holes.
  15. Rooney140

    taking the XR200R the LONG way

    My 83 XL200R when stock with 13/45 gearing and the 5 speed would top out about 62 reliably, put quite a few miles on her that way. Downhill and tailwind would get a few more mph. I have since installed an XR200 6 speed with a little more compression and a little better cam but otherwise stock head. I have been able to go 14/45 and maintain the low end but still top out about 60. After that it just gets too buzzy, even with the XL's rubber mounted bars and pegs. It could be the heavier piston, the cam or the undersized carb but it seems to run out of rev's sooner. I can't quote the exact ratios from memory but the top gear ratios between the 5 and 6 speed trans were pretty close, both mildly overdriven. My 98 XR200R is all but street legal, with the stock motor and gearing. It doesn't have a speedometer, but I would avoid the 8 mile run into town at 55mph on that one. I would guess about 50mph on the fire roads for a few miles is what I feel comfortable with. I have been known to swap front sprockets day to day depending on what my plans are. Years ago my bike got me to work Monday to Friday and tackled sandy Michigan single track on the weekends. It takes all of 10 minutes to swap cogs and adjust the chain, maybe you can plan your route accordingly.