2001 XC200 Restoration Project

[Lincolnlock]

So I decided I needed a new project. And why not start with a $400 2001 xc200? The bike needs a ton of work obviously. It didn't start when I bought it, but a couple of new carb jets and it started right up. The bike sounded ok, but after a couple of minute of running the engine shut off and the kick start was really hard to push down. Turns out the lower connecting rod bearing was starting to lock up. Oh well... So I'll post updates as I go. I still need a few more items to put the engine back together. It should be a fun winter project anyway.

 

[bowhunter007]

So I decided I needed a new project. And why not start with a $400 2001 xc200? The bike needs a ton of work obviously. It didn't start when I bought it, but a couple of new carb jets and it started right up. The bike sounded ok, but after a couple of minute of running the engine shut off and the kick start was really hard to push down. Turns out the lower connecting rod bearing was starting to lock up. Oh well... So I'll post updates as I go. I still need a few more items to put the engine back together. It should be a fun winter project anyway.

I've never ridden a 200cc GG. Should be a fun bike...especially at Walker.

 

[Zman]

Just did the same thing for my son's 200. While you are in there you may want to consider replacing the other bearings in the trans.

I believe these are the correct transmission bearings but double check against what is in your trans.
Bearing #
Counter shaft bearing 6305C3
Countershaft Seal 30x40x7
Clutch bearing 6205Zc3E
Trans shafts 6203c3
98-02 Crank 63/28c3

 

[pscook]

Great find! Good thing you found it first.

Quick tips- Crank nut on the water pump side is reverse thread. YZ Flywheel puller is a perfect fit. And Bob Piper at North Tahoe Motorsports will hook you up for all of your hard parts and any tech data you need. Good prices, fast shipping, and good guy. Here's a link to one of his ebay ads- http://www.ebay.com/itm/TOP-END-WOS...Parts_Accessories&hash=item540245baf2&vxp=mtr

Drop him a note to see if he has 200 stuff, I would think he should.

Also, the only thing different from the 200 to the 250/300 is machining of the cases, crank, and top end (including jug). The chassis are the same, if you didn't know this already.

 

[Zman]

Phil - Are you sure about the crank nut being left hand thread? I did a 2002 and a 2004 EC200 recently and I could swear the clutch side crank nut was a traditional right hand thread.

 

[pscook]

Phil - Are you sure about the crank nut being left hand thread? I did a 2002 and a 2004 EC200 recently and I could swear the clutch side crank nut was a traditional right hand thread.

On my 2002 300 it was reverse thread. Lefty tighty and righty loosey. Of course, an initial inspection of the lead-in threads will tell the story, but I am certain that the primary nut is reverse.

 

[Lincolnlock]

Well... I got the crank rebuilt with a cr250 rod kit. Then I ordered a truck load of parts. I put the crank bearings in and bolted the cases together. The transmission would only spin a 359 degrees and then lock up solid. So I figured out why the bike was parked. The secondary pinion has a tooth that is about to fall off. So I still need to source another one of those. Other than that gear, the bike would be running again. Oh well. Let me know if there is a used gear I could purchase. This bike project is running over budget.

 

[Zman]

You will not be able to ride it very far that way. That is a bummer.

 

[PEB]

Sam which gear is the secondary pinion?

 

[Lincolnlock]

Well, no one in the world seems to have one of these gears. If anyone know of one, please let me know. It is part number: ME25636076

 

[jt633]

Try a fella on here by the name of jim cook very knowledgable good guy i just spoke to him today he may have what you need

 

[Lincolnlock]

Thank you for the reply. I found one in France. It's half the price of what I can buy one in the states for, even with shipping.

 

[Lincolnlock]

Well, I've been pretty busy with things but I've managed to get some work done on the bike. What a pain getting parts for these things. Just for future reference, the vendors in Spain, France, and Germany are much cheaper than the states even with shipping. Also I've had really good experience getting the correct parts the first time. I rebuilt the suspension, wheel bearings, new plastics, all new transmission bearings, new piston, water pump seals, reeds, air filter, muffler repack, crank bearings, and a new rod. It's getting pretty close to being ready to fire up. Here are a couple of pictures.

 

[Lincolnlock]

Well, I've been out on the bike a whole bunch and I need more bottom end. It's super fun to ride but there isn't quite enough power for me. Has anyone tried to use a 300 cylinder on a 200 before? Just curious.

 

[desertgasser300]

Well, I've been out on the bike a whole bunch and I need more bottom end. It's super fun to ride but there isn't quite enough power for me. Has anyone tried to use a 300 cylinder on a 200 before? Just curious.

A 300 jug will not fit on the 200. 250 and 300 are interchangeable, but no 2hundy! Sorry!

 

[Rick]

Well, I've been out on the bike a whole bunch and I need more bottom end. It's super fun to ride but there isn't quite enough power for me. Has anyone tried to use a 300 cylinder on a 200 before? Just curious.

A 2k3 will help, or a fww. 13/50 or 51 gearing is pretty good. Squish mod, play with jetting.

 

[Lincolnlock]

I already have a flywheel weight. Also it has 13/52 gearing. I just ordered a 12T for the front. Hopefully that will help a bit. The trails up here are super tight and 2nd gear is just a little tall so hopefully the 12t will help some. I was under the impression that you could install at least a 250 cylinder? I guess I'll do a bit more reading. Other than the WP forks flexing a bunch when pushed hard, the bike is super fun to ride. Maybe I'll look for a fork upgrade.

 

[djroggen]

No crank is different on 200. 250 and 300 interchange.

 

[hannesd]

jetting correctly for your elevation/temps and squish mod should do more then enough.

 

[bowhunter007]

I'm familiar with the terrain Lincolnlock favors...It just may not have enough grunt for his tastes.