Cowling swap

[honda1k]

Hey guys I ran into a problem doing my cowling swap. I have a 1994 xr6 carbureted 200. I switched to a 1998 v200 the newest style cowling. Anyways I'm having a problem with my sound attenuator hitting the bottom cowling and the locking latch for the top half is hitting as well any ideas?

[Smalltownbassin]

Just to be clear, did you mean xr6 150? Otherwise, just a couple questions...The 94 cowl has the 2 side/rear latches and one front correct? The newer cowl has the one front and single rear latch with v6 stamped in it right? Do you have the older aluminum attenuator or newer black plastic one? I may be wrong but i think the attenuator would be the only difference. The black plastic attenuator should fit in either one. If you could take a picture im sure anyone here could point out the issue. Im assuming you dont have spacers behind the carbs either.

[honda1k]

Thanks for the reply Smalltownbassin. Correct I went from the three latch style 94 cowling to the newer style one in the front one in the back latch I have a 2.5 200. You can see in the picture where the float bowl is hitting the lower portion of the cowling and the black plastic attenuator won't fit hitting the lower and the latch.

[honda1k]

[honda1k]

Here's a picture from the front with the attenuator against the carburetor.

[David - WI]

I think Chris Carson posted about that recently... if you have the extra 1" reed spacer, the attenuator won't fit and you have to grind some of the pan away???

[honda1k]

I think Chris Carson posted about that recently... if you have the extra 1" reed spacer, the attenuator won't fit and you have to grind some of the pan away???

I don't have a spacer the manifold is right up to the block cause I just put a set of his reeds in I might have to do some kind of modifying or put the older cowling back on. I believe the fuel injection intake manifold is shorter?

[David - WI]

Not sure, my EFI 200 is in storage 60 miles away or I would look... but I just replaced that front latch before I put it away and didn't remove anything else so I know there's clearance in front.

[honda1k]

Something is really strange I thought this was supposed to be a direct fit no modifications I did all my research on to it. I don't know this is what I come up with for right now I would like to fix it right.

[David - WI]

Is there any way you might have the brackets on upside down... making the lower pan sit too high?
(Don"t know if it"s even possible -just a thought.)

[honda1k]

Is there any way you might have the brackets on upside down... making the lower pan sit too high?
(Don"t know if it"s even possible -just a thought.)

I was wondering the same thing. I don't know I just pulled my old cowling off and put the new one on never fooled with the mounts or anything. I'm gonna check tomorrow. Thanks

[David - WI]

I was wondering the same thing. I don't know I just pulled my old cowling off and put the new one on never fooled with the mounts or anything. I'm gonna check tomorrow. Thanks

Then I wonder if the mounts are actually supposed to be different part numbers (different either in height or front/back location) for the two cowls?

'96-up front bracket:

[honda1k]

Then I wonder if the mounts are actually supposed to be different part numbers (different either in height or front/back location) for the two cowls?

'96-up front bracket:

Same part numbers

[Smalltownbassin]

Yes, efi plate is lower profile than carb but that doesnt matter because both fit with tons of clearance. Those look like WMV carbs which also fit with tons of clearance. It looks like you are exactly an inch forward somehow. Check your lower cowl brackets like others said. That would be the only squirrel to chase at this point. Looking at the gap around the mid at the bottom of your lower cowl, do you have alot more space in the rear? Were you even able to connect your exhaust relief in the lower without stretching the crap out of it?

[roadkill636]

I have thoes brackets.. pm me