[DIY] 240cc Phantom Project

[am92]

Earlier on you indicated you upsize to #130 main jet to match the larger cc engine. If the stock main jet is #132 isn't that downsizing? I read on forums that Honda Tiger 200 (made in Indonesia) which uses the same phantom engine has a stock main jet of #120. Any idea the huge difference?

[wdwflash]

I'm working with the specs for a Honda CRF230F not a TA-200 as most of the internals in my bike are the CRF230F.(223cc)(piston, crank, rod, cylinder, cam, cam chain, CDI). The stock TA-200 is #35 pilot and #132 main. The stock CRF230 is #42 pilot and 102 main. The BBR Motorsport web site ( I have their hot cam and hot CDI) lists with a big bore 240 kit and upgrade filter/pipe to use a 42 pilot and 130 main. I'm also running a 11-1 compression Wiseco piston. I have only been able to start my bike and idle it as the weather sucks and I'm still doing some wiring upgrades, but as is its running very rich, I will probably switch back to the stock TA-200 pilot jet of #35 and see how that is/work my way from there. Until I'm able to get out on the road, I won't really know about the main jet. The only thing I could think of on the #132 main on the TA-200 and the #130 (stock #102)on the CRF230F is that the needle may be a different diameter, but I have already done the needle upgrade (raised the needle) to my carb so I figured I would go with the mod'd CRF 230 main jet, or the Phantom has a cat and the CRF230 does not. The two carbs are different, but work on the same (variable-venture, slide-type carb), and they use the same type of jets (same outside diameter/threads.)

I'm not sure if the Tiger has a catalytic converter, but the Phantom does and this could have something to do with the difference in jets. The specs show that the Phantom is putting out just a little more HP than the Tiger. (bigger main jet?)

Just a note. Three good upgrades for the Phantom are the raising the needle trick, the BBR CDI and BBR CRF230F hot cam. In Singapore you probably can't get rid of the cat, but here in Cambodia they could care less and I have the Chaing Rai Saddlebags duel pipes. (sound real nice.)

[wdwflash]

I got the engine put together and back in the bike. It started and ran, but after some time and warm up it blew a lot of smoke. ( When I first stated it, it was inside my front room so I couldn't run it for very long, but later routed the exhaust gas outdoors and got the smoke.) I did a compression check and got 70psi. Stock should be 170psi and with the Wiseco 11-1 piston it should have been a lot more. I took the engine out and found that the piston rings were defective from Wiseco. After checking with my nephew in America who is a certified/trained auto mechanic he said that there has been a lot of problems with Wiseco piston rings lately. I compared the Wiseco rings to the stock ones and the top ring was all wrong. In cross section it was rectangular when it should have had a slant on the top inside edge. This could be why oil was allowed to pass it.

 

I sent to America and ordered a stock OEM Honda CRF230F piston and ring. Since I had the engine back apart I decided that due to the crappy low octane petrol/gas here in Cambodia that I was better with the stock 9-1 piston than the Wiseco 11-1 piston. I just got the new piston and rings and will be installing them asap.

Edited September 12, 2016 by wdwflash

[wdwflash]

The Super Phantom is finally finished. Although monsoon rains keep me from riding it, its alive. It took over one and a half years to complete (time out for shoulder surgery). It is bored, stroked, head is ported polished, and relieved. All emission controls have been removed, duel exhaust installed and carb upgraded. It has then following

 

New head (ported, polished, relieved)

New valves

Heavy duty BBR Motorsport valve springs (CRF230F)

High performance BBR Camshaft (CRF230F)

New piston/rings (Honda CRF230f)

New cylinder (CRF230F,223cc)

New crankshaft/rod(CFR230F)

New bearings/seals

Completely new transmission

Barnett clutch

BBR Motorsport Rev Box CDI(CRF230F)

New valve train (CRF230F chain, etc)

CR Saddlebags duel exhaust

CR Saddlebags hard cases

CR Saddlebags crash bars

Driving lights.(lots of new wiring)

Big Bad Max air horn (new wiring)

Skull tail-light.( Almost had to re-wire the whole bike to install this)

Skull n' Bones license plate holder (relocated from stock position)

Chromed n' flamed tank with 10 coats of clear coat.

New 13k tachometer

Skeleton mirrors

CR Saddlebags foot boards

K&N air filter

Shorty Gas shocks

150/80-15 back tire

Custom air deflectors

New brake systems

[wdwflash]

[wdwflash]

[wdwflash]

[wdwflash]

[wdwflash]

[wdwflash]

[wdwflash]

[wdwflash]

The Super Phantom is finally finished. Although monsoon rains keep me from riding it, its alive. It took over one and a half years to complete (time out for shoulder surgery). It is bored, stroked, head is ported polished, and relieved. All emission controls have been removed, duel exhaust installed and carb upgraded. It has then following

 

New head (ported, polished, relieved)

New valves

Heavy duty BBR Motorsport valve springs (CRF230F)

High performance BBR Camshaft (CRF230F)

New piston/rings (Honda CRF230f)

New cylinder (CRF230F,223cc)

New crankshaft/rod(CFR230F)

New bearings/seals

Completely new transmission

Barnett clutch

BBR Motorsport Rev Box CDI(CRF230F)

New valve train (CRF230F chain, etc)

CR Saddlebags duel exhaust

CR Saddlebags hard cases

CR Saddlebags crash bars

Driving lights.(lots of new wiring)

Big Bad Max air horn (new wiring)

Skull tail-light.( Almost had to re-wire the whole bike to install this)

Skull n' Bones license plate holder (relocated from stock position)

Chromed n' flamed tank with 10 coats of clear coat.

New 13k tachometer

Skeleton mirrors

CR Saddlebags foot boards

K&N air filter

Shorty Gas shocks

150/80-15 back tire

Custom air deflectors

New brake systems

[amit2410]

awesome.. would love to see a video of ur bike..maybe a walkaround..sound and a ride

[wdwflash]

I was asked for a guess on HP, so I took a guess using my mechanical background (Marine Engineer, Diesels to 6000hp, steam to 35,000hp building/rebuilding cars/motorcycles). Its only a guess. Personally I could care less about HP etc. It was a project to keep me from getting bored in retirement.

 

Carb: I drilled the relief hole in the top of the slide for better response and the thin washer under the slide needle trick since no one I know makes a carb hop-up kit for this carb. (Dyna-Jet is usually my go to company.) Later after some running I will play some more with the jetting.

 

Since it is still monsooning here,(Cambodia) I'm not really going to take it out for test rides yet.

[wdwflash]

Between thunderstorms I finally got the 223cc Super/Monster Phantom on the road. Its not broken in yet and I only had a few minutes, but it really wanted to take off. The combination of bigger cc-CRF230F parts, BBR Rev Box CDI, BBR Hot cam and the head work really make a difference. The Barnett clutch is oh so smooth. I can't wait for some dry weather to put some miles on it and see what it can really do. BTW/ Living in Cambodia sometimes has its advantages over Singapore (not many, but some),I was able to take off all the emissions. I drilled, taped and plugged the emissions in the head and took off all the hoses/plugged the carb holes.

 

[wdwflash]

If you go to YouTube and type in "Honda TA200 Phantom high performance" there is a video of the Super-Phantom running.

[am92]

Great mod man. Sounds really good. Did you install twin exhausts?

[wdwflash]

Yes duel exhaust. Its from Chiang Rai Saddlebags in Thailand, but I don't think they make it anymore. I didn't like the fiberglass packing it came with and installed real motorcycle muffler fiberglass packing/wrap. It sounds really good and gets rid of the restrictive Cat. Have taken it out on a couple short rides and it really moves for a 223cc bike, that is a 223cc full race engine bike. Its a 223cc that thinks its a 500cc. All the mods really make a difference.

[shazam89]

Wow nice! Too bad it's illegal in sg.

[wdwflash]

I've been doing a little riding and breakin of the SuperPhantom. Man! Its a 223cc bike that thinks its a 500cc bike. With the porting/polishing/releaving, carb upgrades, BBR Motorsport high performance cam and CDI/hot coil it really moves. With the CR Saddlebags duel exhaust that gets rid of the Cat the exhaust note is great. While you can't have the duel exhaust in Singapore, I'm sure the BBR CDI/hot-coil and BBR Motorsport hot cam would be an up grade that would pass your emission tests and wake up the Phantom. (no Emissions here in Cambodia and if you ride a 125cc bike or smaller, no license.)

[weian]

that is one dope Phantom. great job @wdwflash!

[wdwflash]

I took all the emissions off of the carb (I can do that here in Cambodia), and fiddled with the jets, but still can't find a good balance. The carb is 28mm and I believe that is the problem. Not enough air flow. I ported, polished and relieved the intake/exhaust ports in the head to a much larger size since I was going with a high-lift/long-duration cam and have gone to 223cc. I'm looking at a flat-slide 30mm carb on aliexpress. One guy in Siem Reap has gone to a bigger carb from a Honda XL230 that is bolted directly to the head and has gotten more power and good results. Bolting the carb directly to the head, I would be worried about heating the fuel in the carb, but he says he has had no problem.

 

See: Facebook, Phantom Riders Cambodia.

[ohoooterso]

nice mods

im from indonesia,btw the largest size of tyres i tried was 160/60-17 rear tyre.

had to take off the chrome chain cover...

i have seen ur super phantom on youtube,did you take off the chrome chain cover too?

[KwanYu]

Happy New Year.. good old phantom bikes. own it for 14 years.

[Rocky101101]

Hi wdwflash You mentioned that you finally got a TA200 shop manual, I have been beating my head against the the wall trying to find one and getting fake leads with viruses everywhere, would you consider .... for reasonable remuneration sharing a copy, please let me know ASAP