200x xr200 6speed conversion

[jenndnn3]

Those of you the have the 200x 6 speed Conversion. Which Cases did you use? The xr's or the 200x's? Thanx Jen

[Glenn]

I think you'll need the 200X cases for the kick starter side to accomodate the gears that allow it to kick forward.

[short4stuff]

I dont know but what I do know is I have 2 left side xr covers .. atleast I think they are xr .. clutch covers and they are different than the 200x ones. I dont know what year cases I have but they have bearings on the "primary" kick shaft (the one that goes to the center cases) and the 200x one doesnt.. Plus on the inside they are different too. I wonder if they do interchange..

[jenndnn3]

Well the inner cases are the same. It is the outer that is different. All because of the kicker. I double checked today after bearing issue, but it was just a fat wrong bearing. I was just curious which cases people used?

The xr vs 200x differences

6 speed vs 5
decompression vs non
cam is different
MMMM THE Crank is different, but this is so subtle most wont catch the difference.
kicker shaft different
outer covers different
the stator cover is different setup for one coil, however you can use either one.
compression therefore different piston
cdi is different (I think) I really didnt look at that.

There is some more subtle changes, but I cant think of em right now...

[bryan raffa]

I know it's been a few years but do you remeber what you used now? My main concern is the kicker shaft..

[jenndnn3]

Inner/internal cases all internals xr200... Exceptions outer cases, electrical and full on kicker assembly... This one I cannot remember I am not sure if I used the starter gear of the 200x or xr the one that set to the kicker assembly itself.. To get the forward kick you have to use the 200x kicker shaft. SO full on kicker...

Internal lower cases themselves are the same...

[bryan raffa]

Inner/internal cases all internals xr200... Exceptions outer cases, electrical and full on kicker assembly... This one I cannot remember I am not sure if I used the starter gear of the 200x or xr the one that set to the kicker assembly itself.. To get the forward kick you have to use the 200x kicker shaft. SO full on kicker...

Internal lower cases themselves are the same...

so that means Im still stuck with the 200x kickstart problem.. Im gonna try the spring from a 200xr shaft on the 200x shaft..theres got to be a solution to the problem rather than trying to hunt down a overpriced discontinued kit.. thanks jen :headbang:

[jenndnn3]

Oh I apologize,,, Yes the springs they work... I need to relook at my schemes again been about 2 + years But the internal spring i was sure matched..
Alot of time its just easy to say use the whole 200x kicker system...

You mentioned Shaft, so I was concetrating on that...

I will look at the schemes in a bit

Which spring is giving you the issue?

[bryan raffa]

the one that was recalled..(Ratchet spring)I dont want issues after it's together. it was too weak of a spring.. so I was thinking that the spring off a newer xr would work

[bryan raffa]

heres a 96 and a 99 xr200 and the last is a 200x .. they look the same.. I was thinkin of swaping the spring

[jenndnn3]

Yeah the spring IF I recall correctly were a matched thing... I think I even Sent Howdy a note on this cause he had the last of the rebuild or fixed kits... I know for sure the other spring was matched as well,,, The clip/hook part was notorious for breaking on that one..

I am not sure if they changed on the newer XR's much.... But check the measurements,,, I would gamble and buy the spring... I will look into this as well..

There was another piece in there igsignifacant(SP?) that was the same as well.. I remember thinking back then I used the least worn pieces on the 2 different engines..

[bryan raffa]

Howdy led me in your direction,, that why I brought this up. When I get my 2 xr motors at the end of the month..Ill let ya know what I find..

the fox says the one stiffer spring he saw for a 200x had red paint on it..

also what I would like to know is,,,did the XR motors have the same problem with the kicker gears? if so then the Ratchet spring wouldnt work anyways..but thats what were gonna find out:D

[jenndnn3]

That why I put a flip lever decompression on it...

But from what I understand they did not have the same issues,,, Remember they did not have the extra gears for the going forward action

[bryan raffa]

correct..Im just looking to swap the spring.. for a stiffer one so the gears dont slip..all that kit was ,,was a 200x shaft with a stiffer spring that it.

[jenndnn3]

I would Call in and see if you can get the measurements or mic that spring and compare to the 200x... The only thing possible maybe would be a fatter/wider spring which may hiccup the thing... But if the part #'s match from the 80's on I think you will be fine here but again that is a slight gamble but I am sitting at above 80% sure...

The biggest thing I saw with the kicker until the outer case was on how sloppy everything "floated" within the inner cases as well, which in turn may have also been another issue with 200x kicker.. But that is a true guess on my part there and trying to remember is not good... If I recall correctly looking over the whole thing it was indeed a easy to break down area and truley understood why those 200x's had such trouble there...

[jenndnn3]

Oh yeah I forgot another person to chat with I think is 200xbasket as I am almost postive he did this conversion as well...

His memory can maybe serve better?