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Old 10-30-2011, 03:37 AM   #16
Weldangrind   Weldangrind is offline
 
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Rusty old thin steel doesn't cooperate well with a MIG, but a decent TIG welder might be able to patch it. In the case of my XL, I just chopped off the offending section and started again. I bought some exhaust tubing that was the correct diameter and started welding.
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Old 10-30-2011, 03:39 AM   #17
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BTW, I wouldn't be surprised to learn that a similar year XR200R muffler would be a bolt-on, if that helps to expand your search criteria.
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Old 10-31-2011, 11:21 AM   #18
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Quote:
Originally Posted by SpudRider
Quote:
Originally Posted by FastDoc
Well the leaks are fixed. I was able to slightly tighten the rocker bolts and that's all it took. :P

I ground away the rotted portions of muffler. Not much good metal left!

I attempted a repair with some exhaust repair putty and some pieces of metal from a cat food can of all things. I have a feeling I'm gonna need a muffler. :wink:
It's too bad the cat food can repair didn't work. :? I bet the cat muffler would purr meowwwwwwwwwwwww! :P

Spud
I don't know, it may work! It hardened hard as a rock. I'll sand it smooth(ish) and paint it and run it till it breaks :P

Meow 8)
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Old 10-31-2011, 11:22 AM   #19
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The bike is purring now. :wink:
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Old 10-31-2011, 03:00 PM   #20
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Quote:
Originally Posted by FastDoc
The bike is purring now. :wink:
That's great! It's also very fitting.

Perhaps we can now consider you a "catalytic converter." :roll:

Spud
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2015 Zongshen ZS250GY-3 (RX3)
2006 Zongshen ZS200GY-2 (Sierra 200)
2005 Honda XR650L
2004 Honda CRF250X
1998 Kawasaki KDX220

Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894


 
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Old 10-31-2011, 03:11 PM   #21
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Very 'pun-ny' Brother Spud!
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Old 10-31-2011, 10:11 PM   #22
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I patched and painted the muffler. It looks and sounds great. No pic though...

Here's some pics of the bike where I'm at now:





Dual exhaust and dual carbs, single cylinder. Honda...





New CST rubber. :P









This is all fixed now and the newly painted muffler looks great. :P







Strong brakes. 1,000% better than The Dirt Rat's.



Remote adjustable Pro-Link suspension.



Dual carbs.



This is where oil was leaking from but thank God it was an easy fix.
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Old 10-31-2011, 10:14 PM   #23
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I should take some 'After' pics now that's its all cleaned up...
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Old 10-31-2011, 11:40 PM   #24
Weldangrind   Weldangrind is offline
 
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Regarding your brake comment, I found a donor on eBay that provided the same front end that you have. It fell into place on Son of Weldangrind's '83 XR200R; a totally worthwhile upgrade.
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Old 10-31-2011, 11:51 PM   #25
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I think the brakes and the UniTrack suspension are the best improvement of the XR history of upgrades. I would have upgraded The Dirt Rat's front end had I kept it.

The Dirt Rat 2, or R2 as I call it is a worthy successor to the original Dirt Rat. More power, suspension and brakes with the same smooth ride and easy demeanor as the original. I kinda miss the electric start but the 250R starts pretty easily and has automatic compression release which helps.

Plus the absense of a electric starter and battery keeps the weight down some.
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Old 11-01-2011, 12:28 AM   #26
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I have yet to enable the electric start on Son of Weldangrind's XR200R, but I will. It feels like the kicker is going to break, because there's no compression release.

That little bike with a pushrod 230 really hauls!
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Old 11-01-2011, 01:32 AM   #27
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I never heard of a single cylinder engine with dual carburetors. Do you need to synchronize the carburetors? My guess is you don't. :?

Spud
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2015 Zongshen ZS250GY-3 (RX3)
2006 Zongshen ZS200GY-2 (Sierra 200)
2005 Honda XR650L
2004 Honda CRF250X
1998 Kawasaki KDX220

Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894


 
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Old 11-01-2011, 10:08 AM   #28
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That was Honda's approach in '84 and '85, with both the XR200R and the XR250R (along with larger models). With the new four valve head, they chose to keep the two exhaust ports separate, and that style carried through to modern bikes (like Spud's XR-L). I believe that the dual carb arrangement only lasted two years, after which they created a manifold that would allow one carb to feed two intake ports.

Yes, the carbs need to be synchronized, but it's not usually critical. If it was me (and I had synchronization trouble), I'd swap to the later model manifold and one Mikuni.
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Old 11-01-2011, 12:43 PM   #29
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They work like a two barrel carb on a car.

The left carb is the primary and is the only one working at low power settings. It's the only one with an enricher.

At larger throttle openings the right carb kicks in via a linkage for more mixture flow/power.

The idea is a higher mixture velocity at low power which increases tractability and torque down low. This is a priority for an XR. Then to get max power at higher RPM's the secondary kicks in.

It works well but IMHO is needlesly complex. I suspect this is why Honda did away with it after only two years.

I am fortunate my bikes carburation is currently excellent and I have no intention of messing with it in any way! :wink:
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Old 11-01-2011, 07:53 PM   #30
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I had no idea that there was a progressive transition between the two carbs! I knew about the pumper on one of 'em, but I thought they pulled at the same rate. Thanks for that detail!
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