Tlr200 question

47 replies to this topic
  • Tlr200rookie

Posted February 07, 2007 - 05:27 PM


Restoring 1986 tlr 200 reflex for a vintage trials...can anybody help me with proper sprockets and where to find them along with infamous carb kit part #16012-kj2305. also wondering on what to use for exhaust. thanks.

  • WRX Boy

Posted February 07, 2007 - 07:53 PM


I had an '87 TLR200 that I competed locally on for a few years, but its been 8 years since I sold it. If memory serves me correctly, I used an 11 tooth front and a 53 tooth rear. They were both Renthal sprockets and if you can't find the TLR listed, try ordering them for the same year XR200. It is basically the identical motor with different tranny gearing and I believe both front and rear hubs are identical.

On that subject, instead of buying a carb kit for mine, I bought a used carb (same brand and size) off an XR200 from a wrecking yard and swapped out all the guts (needle, jets, air screw etc.). Since the TLR was originally street legal, most of the adjustments on the carb are not adjustable.

As for exhaust, I never swapped the pipe out, preferring to keep mine nice and quiet. As memory serves me, I believe the only pipe ever made for that bike was the old style Supertrapp (much louder than stock). EDIT: just saw some posts about a WES exhaust for the TLR200 so my info here is not correct.

One suggestion I have for you is to also swap out your stock steel rims with some aluminum ones. I picked up some used ones at the same wrecking yard and respoked them myself. The less unsprung weight the better.

Another suggestion is to ditch the stock shifter and linkage. It works great for riding around on the street or trails, but in a trials event you will bash it on a rock and jam it up. I found a very long shifter off some old Yamaha that was the correct shaft size. I bolted it on and put it high and forward. It required me to take my foot off the peg to shift, but I never again bashed it on a rock.

  • Tlr200rookie

Posted February 08, 2007 - 02:12 AM


Thanks for reply,Im going to check out renthal for the sprockets.

  • fiep

Posted February 08, 2007 - 07:03 AM


got sprockets for mine from SprocketSpecialists
rear #441-
front #529x-
just add number of teeth to above part number
fast + friendly service

  • xr7097

Posted February 09, 2007 - 11:17 PM


I,ve been converting my tlr200 for trials also. I found a honda atc185/200 sprocket 10 tooth for mine. Has the same notch pattern. I used a circlip fom a hardware store to hold it on ,as the stock clip with bolts won't work.

  • fiep

Posted February 10, 2007 - 03:56 AM


I did not mean, you need to order stock sizes, I run 12/53

  • Scott Burghart

Posted February 18, 2007 - 05:00 AM


Hi, I just completed a TLR200 build, and it is excellent. Get the WES exhaust system from, tell Bob Ginder I sent you and ask him for the latest TLR tricks as he is doing up a very special one. The WES weighs only about 3lbs 10 oz. and helps the power substantially. It is also still pretty quiet but has a good sound. I also did the BJ racing fiberglass tank seat and Falcon shocks and my bike weight is down to 184 dry and I still have alloy rims to add. The Honda secret carb mod (slide and needle) was a huge improvement. I have lots of pictures if you would like to see what I have done. I am told by people from 3 countries, so far, that it is the best one they have seen. BJ is working on a 220cc kit which involves some extensive and expensive mods and have also talked about making a batch of 9:1 pistons if we have 6 guys interested. I think they are around $200 each, kind of high but the 220 kit is supposed to be $750 ish complete (ouch!). The Falcon shocks were a big improvement and weigh 1.5 pound sless thatn the stock ones, which was a nice surprise. Theri are also some new shocks fromt he Europe, Classic, tuned by Mck Andrews, available from BPS Engineering in France, and the elusive Rock Shocks, that I can't find much aobut, as well as the Betor shock, which is reasonably priced but I have not tried yet. If you wnat any more info on your project email me and I will send some pics. Good luck!

  • Triumphs

Posted February 19, 2007 - 12:53 PM


Restoring 1986 tlr 200 reflex for a vintage trials...can anybody help me with proper sprockets and where to find them along with infamous carb kit part #16012-kj2305. also wondering on what to use for exhaust. thanks.

Let's hope the aftermarket is a little kinder to the TLR then it was for the TL. As soon as it hit 20 years old Honda turned off the tap and the OEM market disappeared for my old bike!

  • mph_phillips

Posted November 30, 2007 - 06:16 AM


im running an 86 tlr200 engine in my 99 xr200r and iv put a frontsprocket for a xr200r on it,it stripped the sprocket hole,there is a little bit of play on the shaft .i was wondering if any one knows if there is a different size shaft on the tlr then the xr?should there be any play from the sprocket on the shaft when it's new? thanks

  • Kev_XR

Posted November 30, 2007 - 10:43 PM


If you are going to work on Vintage Hondas, get really familiar with this page.
What you can learn is which parts are specific to that model and which are "borrowed" from another model.

TLR200 specific parts will have this part number.
TLR200 '86/'87 XXXXX-KJ2-XXX

Once you know which parts are "generic" and which parts are TLR specific, it makes finding old parts much easier.

I used clutch parts left over from my XR200 to fix the clutch in my SL100.

Visit the ThumperTalk Store for the lowest prices on motorcycle / ATV parts and accessories - Guaranteed

Posted December 30, 2007 - 07:24 PM


im restoring one also im looking for the stock decals or just the honda emblems,send me your pics

  • ramz

Posted January 01, 2008 - 07:54 AM


im restoring one also im looking for the stock decals or just the honda emblems,send me your pics

Here are pictures from the Honda 1986 Reflex sales brochure. I have the hi-rez versions, if anyone wants a set (contact me at < ramz [at] rickramsey [dot] net > I don't do PMs).

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  • auto

Posted April 04, 2008 - 07:34 AM


I ordered the carb kit.It came with a new idle adjustment screw.I thought it should have come with a new pilot jet.What size pilot jet should it have been or what size are other people useing.Mine had a #48 in it.Thanks

  • CRM114

Posted April 04, 2008 - 10:38 AM


The two-valve, four-stroke, 200cc Honda engine is a truly an engineering marvel. With good maintenance it should outlast the user. But it is a little underpowered. Powroll at makes a stroker kit that bumps it up to I think 221 cc. There are several guys over on the Honda XR80-200 forum who have lots of experience with this engine and a lot of good feedback on the Powroll kit.


  • Murray_Gray

Posted April 05, 2008 - 05:28 AM


Scott...what is this "Honda secret carb mod" and where can you get one...I HATE that stock carb!

Murray Gray


Posted April 05, 2008 - 06:07 AM


:prof: my carb is trashed idle fine,give it gas it dies and floods,i heard its an xr100 crab?

Scott...what is this "Honda secret carb mod" and where can you get one...I HATE that stock carb!

Murray Gray

  • Pro_Marinero

Posted April 05, 2008 - 06:17 PM


I'm just in the process of putting an XR100 carb on my 'flex. 105 main jet with 40 pilot. Here's a good writeup from a guy who found it out for himself:


  • auto

Posted April 06, 2008 - 07:54 AM


I was able to buy a #42 pilot jet.This jet and the needle from the kit helped big time.The motor idles and take the gas good now.I'm still fighting with the float level.It seems the motor needs as much fuel level it can get.Just short of over flow,to run good.Right now it's running good enough that I'll take it to the MAVT event next weekend in Delaware.

  • auto

Posted April 15, 2008 - 08:06 AM


After Sundays event I feel I do need a new carb.What are the options that will bolt on and fit the air boot? Model/years? It was supriseing how many reflexs are showing up at mavt events.

  • DenialDeath

Posted April 29, 2008 - 05:59 PM


What is the length of the stock or even the aftermarket shocks on the TLRs?


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