1987 XR200R. red dirt redemption

[Hurco550]

So from there I decided to stop into my local shop where a buddy of mine parts out bikes. We came to a trade deal on a complete xr200 motor that had been stuffed (in a pretty jankey manner) into an rm125 frame. We yanked the motor out and I brought it home to again find some unsavory bits o metal when I drained the oil, so once again, exploratory surgery is in order. I'm hoping that between the two lumps I can put one together though.

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[MCKAY34]

looks awesome, cant wait to see how this one turns out!

 

[clem]

Should have taken the whole RM and left that motor behind. Haha. Or go find a 2004 on up CRF450 and smoke everybody else on the trail!

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[Hurco550]

Found where the metal chucks came from.

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[trek97]

What do you think causes this?

Sticky grudgeon pin, not allowing the piston to move freely on the rod?

 

[Jimbonaut]

Enjoy reading your builds Hurco, looks like this'll be a bunch of fun too

 

[Hurco550]

What do you think causes this?

Sticky grudgeon pin, not allowing the piston to move freely on the rod?

I'm guessing it's a result of running this thing without an air filter, or low on oil, or to hot, or maybe all 3 at once lol

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[Hurco550]

Enjoy reading your builds Hurco, looks like this'll be a bunch of fun too

Glad to have you!

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[Mr.E]

Lamest bike ever. Might as well ride a bicycle. Xr200's are worthless

 

[Hurco550]

Got a few minutes to break the cases apart tonight and found the rest of the piston that decided to spend it's fragmented days both behind the oil pump gear drive housing and the biggest pieces in the bottom of the case. I also found that the small end of the con rod was a bit worse for wear, so next I am going to tear down the original motor and swap in the crank.

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[Hurco550]

Got a little time tonight to finish getting the chucks of grenaded piston removed and giving the cases a thorough cleaning. The motor got fresh gaskets and seals and a new set of clutch frictions and plates as well as the better of the two cranks installed.

Back together she goes

Just waiting for new rings and a few bits to come in and we'll back in business.

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[canyoncarver]

I heart assembly lube.

 

[adventurco]

That was quick. Nice!

 

[Hurco550]

I heart assembly lube.

#ultraslick

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[Maritime]

Ha. nice.

 

[Hurco550]

The original jug that was already bored oversized is actually within a half thousandth of straight and round. Piston clearance is right at .0035" on the weisco that was in it, and the claimed max service limit is .004", but I'm cheap and it's a play bike, so a quick hone to break the glaze and I'm gonna run it with a fresh set of rings.

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[jordandogtown]

Subbed. I'm a sucker for a good ol XR resurrection

 

[Hurco550]

Just shy of a decade later, I finally got the motor back together. Fresh seals, gaskets, rings, cam chain, tensioner spring and guides, hopefully she'll be good to go. If the stars align it'll be back in the frame tomorrow.

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[cxman]

hurco
knurl the piston then it will be good the knurls will hold oil to

 

[Aussie Steve]

Cxman, educate the ignorant. What do you mean by knurl the pistons? Thanks

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