Bodywork/replacement plastics:
You can get stock replacement plastic from your local Honda dealer, or you can get aftermarket plastic from companies like Acerbis, Maier, or Polisport. The following is a description of what's generally available and most of the color choices:
1. Acerbis: Lower fork covers (85-98 white), Side panels (96-98 black, white, red), Skid plates (92-97 white), Fork blades (90-98 white), Disc guards (96-98 purple, white, black), Frame guards (92-98 white), Front fenders (90-98 black, red, purple, white, silver), Fuel tanks (88-98 white), Rear fenders (90-98 white, black, red).
2. IMS: Enduro series fuel tanks, 4.9 gallons (84-95 natural, orange, red, white) and their 4.0 gallon tank (84-98 black, blue, natural, orange, red, white).
3. Maier: Front fender (86-98), Rear fender (81-82, 86-95), Disc guard (84-98), Side panels (86-98), Headlight shells w/numberplate (84-95). All Maier plastic is available in black, blue, flash red, green, purple, red, white, yellow.
4. Polisport: Headlights (86-02), Rear fender (86-02), Front Fender (86-02), Handguards.
I don't recommend putting CRF shrouds on XR like the one shown below. It could only mess up your gas tank since surgery has to be made inorder to fit the plastics. Plug & play shrouds made of fiberglass or hard plastics also has unpleasant effects like vibration and rusting tank (moisture would accumulate underneath the shroud). Same goes with CRF-ing the entire seat and sidepanels. Unless you're into bike shows, modding the tank and seat is just a bad idea. It becomes your achilles heel on trail rides.
The stock handlebars are good old plain steel, and will hold up for a long time, through many crashes are great when you're learning, but they are pretty heavy. Many companies like Renthal, Answer, Moose, and White Brothers all offer aftermarket bars for the XR that are quite a bit lighter, and in some cases offer better shock absorption. A popular choice for the XRs is an aftermarket bar in the "CRF-High" bend style. These bars have a taller rise, and are more comfortable if you're spending a lot of time standing up.
Many companies such as Summers Racing, Maier, and Moose offer guards for the levers and bar ends to fit most any handlebar. Most guards are anodized aluminum, and can be purchased with or without additional plastic shrouds to guard your hands from flying roost. They all generally do a good job of protecting your levers and hands from brush, and the addition of the plastic guards works great for mud. Summers Racing has a different type of inboard mount available that bolts to the top triple clamp, rather than the handlebars, to theoretically allow the bars to flex as designed, without the restriction of bar mounted clamps.
The stock chain for stock XR 200 is a D.I.D 520 o-ring chain, and holds up quite well if cleaned regularly and kept well lubricated with your favorite chain wax (even used motorcycle oil will do).
The sprockets seem to wear out a little faster than the aftermarket units, these being available from companies such as Renthal, Answer, and Sprocket Specialists. If you are replacing one sprocket, it is a good idea to replace the other and the chain all at once to promote even wear.
Rear Disc Brake
XR/XLR 200 comes with a rear drum brake that can be modified into disc brakes through machine shop surgery. Though it seems like the only purpose for this is just to improve the bikes aesthetics (the light weight of the XRs 200 generally does not require any changes in the braking system). You can use a new front disc brake from Honda under bones (wave and xrm) as your bikes rear disc braking system. It’s a lot cheaper compared to buying aftermarket disc brakes for XR or CRF dirtbikes.
Exhaust System
Many aftermarket exhaust pipes and systems are available for the XR, including large diameter head pipes (on the theory that the stock pipe diameter is too small). Most exhaust systems will require carb re-jetting and tuning for best performance, and will also increase the noise coming out the back end. Available pipes for XR200 (locally made):
1. YRS Pipe – Pros: nice sound, performance, lightweight. Cons: the elbow made of lacklustre metal, not made of stainless steel. The canister, though, is aluminium.
2. GCG Pipe – Pros: the looks (pro-circuit replica). Cons: if you are into sound, this pipe is a bit low. Also it did not come with an elbow; you gotta use your rusted stock pipe elbow.
3. Musahshi Pipe – I haven’t got any feedbacks yet but this is how it looks:
