269 replies to this topic

[steelwarrior26 TT Member]

After being without a bike for almost 15yrs I found a basket case..$50.00 and a get it out of here it sits in garage. after cleaning the carb it fired right up. and rewarded me with a oil leak at the base of the cylinder. is this a common thing with this engine?  thanks  Tim

[basilfaulty TT Bronze Member]

Here is a link for changing the crank sprocket on an XR200
http://www.thumperta...=crank sprocket

[PIxr200 TT Newbie]

Greetings all, thanks for the informative thread. Here's my 2010 XR200, these things are popular here in the Philippines because of their simplicity, reliability, and ruggedness. This is my first motorcycle and I love it!



I am in the process of shopping for a disc brake installation for the rear wheel, it's a very popular modification here. If you want to see some really nice 200's check out this website: http://www.motorcycl...searchid=208988

[GeauxKTM TT Bronze Member]

last year my race bike for harescrambles was having issues while at the race so I joking entered on my dads 02 XR 200 and holeshotted somehow, passed 32 people in less thsn 1/2 of the first out of 3 laps. Due to ground clearance/softness the shift lever snapped so i was hand shifting and not much into the second lap the rear brake lever boke so I called it quits.  Great bike, #1 does not wear me out, 2 no choice but to roll out due to mine barely having brakes. Racing in 3 weeks and havent been on a bike since January. All of your info is will be very helpful and I might have some questions. thanks

[2002XR200r TT Member]

why in the hell do they not sell these anymore in the usa?

[sci0nxa TT Newbie]

I think it should be added that the california bike jetting is different. They run extremely Lean!!

pilot screw is set @ 1-7/8 turns out
slow jet: #35
main jet: #102

i was having alot of problems keeping the bike on without maxing out adjustments and choke up all the way at all times. It was only starting with throttle wide open. I rejet the bike to Main jet: 110, and slow jet: 38 and i set the pilot screw to 1-1/2 turns and it made a world of difference.

[dwil4 TT Member]

tons of good info in this post !!

[drifterboy3 TT Member]

so if i were to buy one out side of those years what would i need to do to make it fit? is it minor or just something thats not worth messing with

[snakeriverrangerider TT Bronze Member]

What about brakes?  I didn't see any upgrades for that and that is what they seem to be lacking in the most.  I have an 82' xr200r.

[Smity150 TT Newbie]

Just wondering that if anyone knew that if a crf250r front forks will fit on an 2001 xr200r

[hunterdodge TT Newbie]

im wondering what years parts are capatible with the 91 xr200r....im planning some mods and already big boared and tweeked the fire power to compinsate, did a frame off paint job, frame red and plastic black, now i just ordered all the bearings and bushings, but.....i need to know if i can just pick up any old xr parts such as rear rim....please let me know ! and if i was going dual sport...what size sprockets and where would i get a cheap0 light it ???

Edited by hunterdodge, 25 August 2012 - 03:36 AM.

[chuck4788]

Quick Draw started this thread on modding XR200s in 2006 and posted in 2010 that this thread should become more of a guide rather than detail information on mods.  I think that is a good idea because this thread is a sticky with reference information and filling it with detail questions and answers adds clutter making it more difficult for others to find info and links.  So if you have a specific question about  your XR you will get a faster answer by posting a new topic, which will help preserve this thread as an easy to use resource.

To help with that I put together the following list of recent info and links, not inclusive as new info is being posted all of the time. Also please recognize that using the TT search feature will uncover much more info but this list will get you started:

General mods, post #1 in 2006 by Quick Draw, this is the one that started it all: http://www.thumperta...ost__p__3081376

Honda part numbering and model codes, Post #237: http://www.thumperta...ost__p__8765498

Summary of XR185/200 model changes thru the years, Post #238: http://www.thumperta...ost__p__8765556

California carb jetting is different: http://www.thumperta...ost__p__9437542

Cam chain sprocket, changing the crank sprocket on a XR200: http://www.thumperta...=crank+sprocket

Chassis and Suspension: http://www.thumperta...and-suspension/

Cleaning carb:  http://www.thumperta...796&postcount=1  

Crank Sprocket, Changing: http://www.thumperta...procket-xr-200/

Engine Rebuild:  http://www.thumperta...engine-rebuild/

Engine Weights: http://www.thumperta...-engine-weight/

Forks and Shocks, How They Work: http://www.thumperta...st__p__10255385

Ignition Timing, Checking: http://www.thumperta...st__p__10064178

Powroll 218 Build:  http://www.thumperta...roll-218-build/

Rear Disc Conversion on a 230: http://www.thumperta...ake-conversion/

Slipping Clutch:  http://www.thumperta...lipping-clutch/

Uncorking a XR200R:  http://www.thumperta...rking-a-xr200r/

Weight Reduction for XR200R: http://www.thumperta...ad.php?t=815548

Weight Reduction Ideas by ExploringWA in the CRF150/230: http://www.thumperta...9880&highlight=

XR218R by Dwight: http://www.thumperta.../878700-xr218r/

XR in RM chassis:  http://www.thumperta...44#entry8585344

183 lb XR218: http://www.thumperta...0-183-lb-xr200/

240cc Engine:  http://www.thumperta...c-big-bore-kit/

[chuck4788]

One more useful Link, a Dirt Rider review of the XR200R in 2009:  http://www.dirtrider...2_honda_xr200r/

XR100 Gas Tank on a XR200: http://www.thumperta...13#entry9599913

Master and Cia Big Bore Kits in the 150/230 forum; http://www.thumperta...-big-bore-kits/

CDI module testing:  http://www.thumperta...st__p__10302962

Master & Cia big bore and strokers: http://www.thumperta...-big-bore-kits/

Edited by chuck4788, 30 September 2012 - 08:03 AM.

[ViperGTS TT Member]

Any tips on how to add a momentary kill switch on my XR200?


I have a horn switch near the left hand grip which would really be handy; I think it momentarily completes the circuit.

The old style momentary push-to-ground-it-to-frame switches are hard to find here in the Philippines.


I'd like to in corporate it into the horn button as way to quickly shift without the clutch

[XRBEATER02 TT Newbie]

The wife wants to black out her 02 XR200R the front fender was easy to find but I don't believe anyone makes one for the rear. Would anyone know if there is another year or model of fender that would fit this bike so I can see if I can get it in black.

[chuck4788]

Installing Right Side Cover on engine,  a difficult job because of frame interferance with the decompression lever and aligning the decompression cam and the clutch release mechanism. Couple of links:

From 2010 http://www.thumperta...pression-lever/.

And more recently: http://www.thumperta.../#entry10506876

[chuck4788]

Cleaning a bored cylinder by Old School Al (OSA):

http://www.thumperta...0#entry10540838

[NZRob TT Newbie]

Sorry if this has been covered but will a 90 CR125 fork fit a 82 XR200r?

[mrXR200r TT Member]

got a stainless steel pipe from a 600 on my XR200r, don't think it improved performance very much, but it makes the best noise.

[spodeboy TT Bronze Member]

I picked up an 86 XR 200 bone stock. I want to share an exhaust mod that keeps the spark arrester in play and costs nothing. You will notice an increase in power from bottom to top, and a quicker rev. And barely any noise increase at all.

Sitting behind the bike look directly at the end of the stock exhaust. Notice the small exhaust opening. Also notate the flat area surrounding the exhaust opening. Take a 1/4" drill bit and make 4 holes at 12, 3, 6, & 9 o'clock in the flat area between the exhaust tip and the outer edge of the muffler. Because the arrestor is wider than your new holes on the inside it will still be legal. It will also offer nearly 100% more air flow. I have done this on 3 previous XR's including a 250 & 400.

Hope this helps.