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redemn93
04-04-2016, 08:13 PM
So what gives? What am I missing? Pics show the hump/bump or whatever you want to call it in the same place. Caliper has new pads. Rotor won't go on

http://uploads.tapatalk-cdn.com/20160405/bd68b3593c8c268a460276f597587386.jpghttp://uploads.tapatalk-cdn.com/20160405/de3a2354204e2caf319c84fc4bff8a06.jpg


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oldskool83
04-04-2016, 08:15 PM
your missing a front axle spacer up front, that's why its doing that. www.partzilla.com to see how it all goes together

redemn93
04-04-2016, 08:30 PM
I have the spacers. Everything is fully disassembled now. The problem is the rotor will not fit in the caliper. Just trying it on by hand. There were no brakes on this bike when I bought it. I replaced the piston seals and the piston now fully compressed for installation. New pads as well. I have the shop manual for it and everything is in place and matches the pictures but the rotor will not fit.http://uploads.tapatalk-cdn.com/20160405/3d2ac28eeeab05df28702ca317d34660.jpghttp://uploads.tapatalk-cdn.com/20160405/4dfb47642b27fa4b2c97de653de88042.jpghttp://uploads.tapatalk-cdn.com/20160405/10880c50887793e9f4399f7855fb9fe6.jpg

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redemn93
04-04-2016, 08:33 PM
From what I can see the hump is the problem blocking the rotorhttp://uploads.tapatalk-cdn.com/20160405/e0d5042e8ee1bf51b862bffcf4db8e90.jpg but it's supposed to be there according to all the pictures.

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ironchop
04-04-2016, 09:01 PM
The hump just barely clears the rotor when the front end is altogether. Pull the caliper toward you as you are looking at it like the above pic is oriented. The caliper is supposed to slide freely on those pins so the caliper works correctly. If it won't easily pull toward you enough to get the rotor to clear the hump, then you need to take caliper off the pins and lube them. Sometimes a bent bracket is the cause of calipers binding.

In the photo the caliper looks pushed outward toward the end of the pins. Pull it in towards the bracket and try again


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redemn93
04-04-2016, 09:03 PM
Oooooh. I'll try that tomorrow and post back. Thanks.

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YTZ drew
04-04-2016, 09:32 PM
Are you sure that's the front bracket, and not a rear caliper bracket attached to a front caliper? I remember from my basket case build that the brackets are different. I'm in the house for the night, but I can look tomorrow through my extra parts box if you need parts pics.

redemn93
04-04-2016, 09:48 PM
It mounts up correctly and looks like the pics I've seen. If you happen to have an extra anti rattle spring and shim I'll buy that from you. Hopefully I can get these slides unfrozen.

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wonderboy
04-04-2016, 10:50 PM
Ironchop has it exactly right: your caliper needs to slide on the rails further inboard. Below is the pic of mine showing how much more inboard the caliper is compared to the bracket.
229935

You need to make sure that the caliper can slide on #8 and #10.
229936

YTZ drew
04-05-2016, 06:17 AM
If you happen to have an extra anti rattle spring and shim I'll buy that from you.

I'll take a look in the box, if I have them they're yours for the postage. Stay tuned.

redemn93
04-05-2016, 07:45 AM
I'll take a look in the box, if I have them they're yours for the postage. Stay tuned.
Awesome. Thank you sir. I'll include a few extra for your time.

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Mackus84
04-05-2016, 08:21 AM
The anti rattle clip and shim are still available through Honda. Just thought id show ya. Every front caliper part except the actual assembly and original pads are. At least from the look of this fiche.
http://www.servicehonda.com/parts/lookup#/Honda/ATC200XA_(85)_ALL-TERRAIN_VEHICLE_(ATV)%2c_JPN%2c_VIN%23_JH3TB052-FK400006_TO_JH3TB052-FK447345/FRONT_BRAKE_CALIPER/ATC200X-85-JPN-A/2Y14965DAF14965D08A

redemn93
04-05-2016, 10:34 PM
The other pin came out easily. Then I found the stuck pin. This is after scraping it with a flathead. Sitting up soaking in blaster overnight. I'll refill in the morning if it's gone. I already rounded out the Allen head. I should be able to drive a 1/4 Allen key into it tomorrow and give it another shot. An impact may actually do the trick. If not, time for a new caliper.
http://uploads.tapatalk-cdn.com/20160406/ca39cc94891d6f606123707ab2aa85d4.jpg
http://uploads.tapatalk-cdn.com/20160406/abdc5fb5be117c9a5bf96671dc7e4506.jpg

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wonderboy
04-05-2016, 10:49 PM
Keep in mind that the caliper slides on that pin, so if you can figure out a way, just press it out of the caliper. No need to unscrew it to get the caliper off the pin. The hex is just there to unscrew the pin from the bracket. They can be a real PITA, but work it back and forth and it should come out.

redemn93
04-05-2016, 10:52 PM
Good point. Thanks.

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yaegerb
04-06-2016, 12:04 AM
Good point. Thanks.

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If you don't want to mess with it or can't get that bolt out, send it up to me with this kit and pay shipping both ways and we'll call it even Steven.

http://m.ebay.com/itm/1983-1987-Honda-Honda-ATC-200X-Front-Wheel-Brake-Caliper-Rebuild-Kit-ATC200X-NEW-/350887555995?nav=SEARCH

redemn93
04-06-2016, 12:26 AM
Thanks for the offer. I should be able to handle it though. Feel kinda dumb for not realizing that before.

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YTZ drew
04-06-2016, 06:40 PM
I've had a few that I couldn't get free. It's a real pain to set up in a press. I finally gave up on mine and put a kx80 rear caliper on my stock 200x bracket. It's a bolt on. I bought the whole kx rear brake setup for $25 shipped, and then used the master and line to freshen up my rear brakes.

redemn93
04-06-2016, 07:18 PM
That was going to be my next option but here's where I'm at now. The pin is reluctantly moving but bracket is hitting the caliper body body. I'm almost there. Gotta figure this out now.
http://uploads.tapatalk-cdn.com/20160406/80ffe18061aa1189cb95f2926776bf35.jpg
http://uploads.tapatalk-cdn.com/20160406/0f251a674e88c480449a6d70595541df.jpg
http://uploads.tapatalk-cdn.com/20160406/9142c988add8643e0289c7e3b7d0478e.jpg

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redemn93
04-06-2016, 07:20 PM
That was going to be my next option but here's where I'm at now. The pin is reluctantly moving but bracket is hitting the caliper body body. I'm almost there. Gotta figure this out now.
http://uploads.tapatalk-cdn.com/20160406/80ffe18061aa1189cb95f2926776bf35.jpg
http://uploads.tapatalk-cdn.com/20160406/0f251a674e88c480449a6d70595541df.jpg
http://uploads.tapatalk-cdn.com/20160406/7856f22c7cd88f93ad5c458dc42cd24b.jpg

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ironchop
04-06-2016, 07:52 PM
I think I had to unscrew that pin to get the caliper off the bracket but don't recall.

Maybe unscrew the smaller pin. It has a hex base. Then you could swing the caliper up enough to get it to quit hanging on the bracket

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redemn93
04-06-2016, 07:59 PM
Yeah. Pins stuck. Going to try and grab it with small channel locks.

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redemn93
04-06-2016, 08:39 PM
Small pin is out. Tried swinging out. No clearance. Already destroyed the big pin. I may just cut it and find a new pin.

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redemn93
04-25-2016, 02:35 PM
ended up getting a KX80 caliper. all bolted up and working last week. should've done it sooner. thanks for the help guys.