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Old 01-16-2008, 09:12 PM   #241
Klay
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Quote:
Originally Posted by MacNutz
How big a hole did you put in the air cover? And, how many full turns out is the screw? You may still need to richen the bottom end.
My impression is that the bottom end is plenty rich, based on the how quickly I can run it without choke even in the cold. I may need to lean it out.

The hole is 2 1/2 inches in diameter. I have the pilot needle out about 1-1/2 to 2 turns. It's impossible to fine tune the pilot screw in this weather. It's only 12F above and the highs the next few days will be below zero. So I'm just waiting for spring now.
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Old 01-17-2008, 04:30 PM   #242
GuinnesS
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Damn you all!, reading this thread has got the best of me. For some time now I have been looking out for a MT-rat bike and I finally came across this little DR.
For the price of an Irish whistle I picked up a purple frame/seat 97. Aside from; being very grimy, a broken clutch lever, a disintegrated air filter and a gunked up carb, these were the only things wrong with it (so far). Another $50 and a quart of oil sorted this out.

Drilling out the mixture screw and blowing out the various jets/passages has it now running like a top. Even at 200 lbs though I find the gearing (15:45) a little frantic. I would like to go 16:45 or 15:42(40) if anyone can tell me where to source the sprockets...please!
I cannot believe how well this little 11,000 miles motor runs (not power-wise ). No-choke starts each morning are very satisfying. I can run this thing balls out for 20 mins on the highway and when I come to a stop the little engine just settles down to a perfect laxidasical idle as if it were sitting in my driveway
Has anyone found a solution for the rear shock yet? I have a left over front end from an 05 DR650; Clamps, forks, wheel, brakes etc, from a past project.






Bottom bearing on the 200 stem has a 30mm ID as on the 650, top however has a 25mm.


I might try turning down the 650 stem to fit the 25 mm top bearing and seeing if I can make it fit.


I would consider this in the 'free mod' category as aside from the wheel the rest of the front end would be virtually worthless on ebay, so why not try, right?
The 'low' position adjustability (rearranging the spacer placement) of the 650 forks drops travel from 10.2" to 8.7" which should match the DR200's 8' if I slide them up a 1/2 inch or so.
Brakes will be a huge improvement but overall weight should be up a little, though the 650 clamps and stem are aluminium vs all steel on the 200. Given the 80-100 lbs difference between the 2 bikes, the stock springs in the 650 forks should be a BIG improvement. I am not so much looking to turn this into a better 'trail' bike but rather trying to match the spring/damping and brakes to better suit my portly 200lbs. The bike is low enough as it is on its side stand but I am getting into Harley territory when I sit on it the poor thing right now.
Either way this bike is a little charmer, 35-45 mph is just perfect for running errands in the sunshine and enjoying the balmy trades
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GuinnesS screwed with this post 01-17-2008 at 04:37 PM
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Old 01-17-2008, 06:07 PM   #243
MacNutz
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[quote=GuinnesS] Even at 200 lbs though I find the gearing (15:45) a little frantic. I would like to go 16:45 or 15:42(40) if anyone can tell me where to source the sprockets...please![quote]

If you're 200lbs, I'm sure you don't want to gear it up any. You should probably go down a tooth on the front (15 to 14). Anyway, you can usually find the sprockets on ebay.
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Old 01-17-2008, 06:39 PM   #244
GuinnesS
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Quote:
Originally Posted by MacNutz

If you're 200lbs, I'm sure you don't want to gear it up any. You should probably go down a tooth on the front (15 to 14). Anyway, you can usually find the sprockets on ebay.
No I am quite sure I want to go 16 (or 42t), this is not gonna be a trail bike, just running errands mostly, cool moped w/ a bag of tricks if you will. I can currently pull away in second with minimal clutch work. The bike may be short on hp but does have some torque. It has taken its cargo (this fat bastard) over some pretty steep grades, I just want it to relax a little more at 40mph, I am not looking to raise the top speed (could care less)I'd like the revs to chill out a little, 40-45 mph is where this bike will be cruising. GsSteve reports some success with this setup even if he is a touch more slender than myself.
Any other sources for 16t's aside from fleabay? I am not a huge fan of PayPal
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Old 01-17-2008, 06:39 PM   #245
Klay
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Quote:
Originally Posted by GuinnesS
Damn you all!, reading this thread has got the best of me.




I can run this thing balls out for 20 mins on the highway and when I come to a stop the little engine just settles down to a perfect laxidasical idle as if it were sitting in my driveway
Don't you love that? I ran it pretty much flat out for 1500 miles on a trip and it acted no different than if I had just run down to the corner store and back.
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Old 01-17-2008, 06:42 PM   #246
Klay
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Quote:
Originally Posted by GuinnesS
No I am quite sure I want to go 16 (or 42t), this is not gonna be a trail bike, just running errands mostly, cool moped w/ a bag of tricks if you will. I can currently pull away in second with minimal clutch work. The bike may be short on hp but does have some torque. It has taken its cargo (this fat bastard) over some pretty steep grades, I just want it to relax a little more at 40mph, I am not looking to raise the top speed (could care less)I'd like the revs to chill out a little, 40-45 mph is where this bike will be cruising. GsSteve reports some success with this setup even if he is a touch more slender than myself.
Any other sources for 16t's aside from fleabay? I am not a huge fan of PayPal
Mine certainly seems happy withe the stock gearing at 40-45...I wonder if the ratio is not already altered.

For a while front sprockets one tooth larger were available...the company is named earlier in the thread. I have one but it's promised to Ladybug0048 already. Search back in the thread.
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Old 01-17-2008, 06:46 PM   #247
GuinnesS
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Quote:
Originally Posted by Klay
Don't you love that? I ran it pretty much flat out for 1500 miles on a trip and it acted no different than if I had just run down to the corner store and back.

Too right!
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Old 01-17-2008, 07:36 PM   #248
MacNutz
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Quote:
Originally Posted by GuinnesS
No I am quite sure I want to go 16 (or 42t), this is not gonna be a trail bike, just running errands mostly, cool moped w/ a bag of tricks if you will. I can currently pull away in second with minimal clutch work. The bike may be short on hp but does have some torque. It has taken its cargo (this fat bastard) over some pretty steep grades, I just want it to relax a little more at 40mph, I am not looking to raise the top speed (could care less)I'd like the revs to chill out a little, 40-45 mph is where this bike will be cruising. GsSteve reports some success with this setup even if he is a touch more slender than myself.
Any other sources for 16t's aside from fleabay? I am not a huge fan of PayPal
Gotcha. Here's a list of ratios I worked out according to the sprockets that were available from the dealer.
Attached Images
 
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Old 01-17-2008, 10:15 PM   #249
GuinnesS
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Quote:
Originally Posted by MacNutz
Gotcha. Here's a list of ratios I worked out according to the sprockets that were available from the dealer.
42/15 = 2.80 or 45/16 = 2.8125, .......six, one-half dozen
I just need to find the bleemin things.
Klay, where did you find your 16t? I had a chance to get a look at the rear sprocket when I cleaned and re-lubed the chain; 45T. I have not yet checked the front, it may well be a 14T, though everything else on this bike has been left stock by the two PO's. I'll have look in the morning. Right now the bike does feel high strung at 40-45 and while it will get up to 60+ mph (indicated) it feels alot like over-rev. My wife's GTS250ie is doing it's nails at 65 w/ more to go.
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Old 01-17-2008, 10:34 PM   #250
Klay
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Quote:
Originally Posted by GuinnesS
42/15 = 2.80 or 45/16 = 2.8125, .......six, one-half dozen
I just need to find the bleemin things.
Klay, where did you find your 16t? I had a chance to get a look at the rear sprocket when I cleaned and re-lubed the chain; 45T. I have not yet checked the front, it may well be a 14T, though everything else on this bike has been left stock by the two PO's. I'll have look in the morning. Right now the bike does feel high strung at 40-45 and while it will get up to 60+ mph (indicated) it feels alot like over-rev. My wife's GTS250ie is doing it's nails at 65 w/ more to go.
I'll see if I can find the company.
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Old 01-17-2008, 10:53 PM   #251
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Found it, it's a company called Rebel Gears.

http://www.rebelgears.com/

Part number 655-16. You could give them a call and see if they have any around.
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Old 01-17-2008, 11:03 PM   #252
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If you have any trouble finding a 16T sprocket, contact www.procycle.us
They'll fix you up
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Old 01-18-2008, 05:32 PM   #253
MacNutz
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Cool2 sprockets

Quote:
Originally Posted by GuinnesS
42/15 = 2.80 or 45/16 = 2.8125, .......six, one-half dozen
I just need to find the bleemin things.
Klay, where did you find your 16t?
Here is a list of off-road bikes that supposedly share the same output shaft spline.
Suzuki and Kawasaki models:
DR200SE (96-05)
DR250 (90-95)
DR250SE (93-95)
RM250 (82-present)
RMX250 (89-01)
DR-Z250 (01-06)
DR350 (90-99)
DR350SE (90-99)
DRZ400 E (00-present)
DRZ400 S (00-present)
KLX400R (03-present)
KLX400SR (03-present)

Maybe you could use one of these applications to find a 16 tooth.
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Old 01-19-2008, 06:59 AM   #254
BikePilot
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A DRZ400 or DR350 front sprocket fits and 16T versions are easy to find. I got a 16t for my mom's DR200 from sprocket specialist and it works great. She much perfers it with the taller gearing. I was amazed how low it was geared in stock form. I found myself in top gear while still in her subdivision at 30mph or so.
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Old 01-19-2008, 09:25 AM   #255
gwl
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DR is great

I just had to ride the other day. It was just a quick trip to the store but boy it felt good. Took a side road home. It was fun untill I got into some ice, but made it throught. That was two days ago and I am still smiling. Bad news is that the high on Monday in Centeral Oregon is going to be 10 with frezzing fog. Oh well I love that little bike.
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