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Thread: '83 ATC 200 rebuild.

  1. #1
    Join Date
    Jul 2018
    Location
    TN
    --
    11

    '83 ATC 200 rebuild.

    I have never rebuilt anything like this before. Briggs & Strattons galore. Several chain saws and a small block chevy or three but never a Honda. Fingers crossed I don't screw this up.


    The engine ran but smoked like a freight train. Compression test showed 50 PSI. A spoon of oil in the cylinder jumped the compression test to 125 so rings bad, valves good. I got it down and most everything looks great. Cam mic's within spec. No galling or scoring on anything. Looks like rings and gasket set will get the rotating assembly back in order.

    Two bumps in the road so far.

    First is no biggie. The head is made for a cable actuated compression relief. The pull rope cover is not. I have the parts from a donor motor i was given to put a manually operated lever in it's place. I'm reasonably certain that'll work but would like a second opinion. Chances are, I'll never use it anyway, I just don't want the lever flopping around with no cable.

    Second is a big deal. The pulse rotor assembly is screwed. I do NOT know how it ran. A testament to how well designed the motor is. The springs are in pieces. I found the chewed up remains. The rotor is mangled. The advance weights are bent beyond use. The donor motor isn't much better.
    Does anyone have a rotor and the spring weighted advance assembly they would sell. I have several modules and all the housing parts, I just need a usable rotor and the advance assembly. I COULD use just the weights and springs but would just as soon buy the whole contraption if someone has it.

    Thanks for the help. My parts should be in Tuesday and I'll start getting it back together.

  2. #2
    125Mmadness's Avatar
    125Mmadness is offline At The Back Of The Pack Arm chair racerFirst time rider
    Join Date
    Apr 2017
    Location
    McConnelsville,Oh
    --
    151
    I've got one you can have if you pay shipping and a rocker cover for manual comp. release I'd take $15 for it. Welcome to the site.
    1985 ATC125M: Parts
    1985 ATC200S: 84 200S Bottem end, 200x Head, 200x Carb, S&S Cycle Exhaust, Wiseco 10.25:1 Piston, Reground Cam with About 1mm more lift(unknown specs).
    1988 TRX250X
    1983 ATC200E: Total Pile.


    "Bout Tree Fiddy" Master of Thy 22RE

  3. #3
    Join Date
    Jul 2018
    Location
    TN
    --
    11
    Sweet! PM sent.

  4. #4
    Join Date
    Jul 2018
    Location
    TN
    --
    11
    Ok, I just got the rear brakes replaced and adjusted.
    Decision time. I'm missing pretty much everything for the front brake assembly. Do I start tracking it down and put it back or just run it? I'm too old for wild riding so I bet just the back would be good enough. Either way, back burner project.


    Poor old gal. At least she's where someone will try to care for her and enjoy her.

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    Waiting on parts.............

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  5. #5
    Join Date
    Jul 2009
    Location
    South Florida
    --
    5,544
    Make sure to hone the cylinder and check it for roundness , don’t want to see you have to do it twice
    78 atc 90/180cc Dickson Full Suspension
    76 ATC90/180cc Nicholson
    77 atc 90 Dickson Full Suspension
    84 KLT 110/123cc Powroll Racer from 80s
    87 atc 125m stock
    84 atc 200x Curtis Sparks
    84 atc 200x Powroll My race bike from 80's
    83 atc70/108cc Powroll blue Xmas Special
    81 atc185s HP-ATC full suspension

    Performance Shop is Open PM me for Service

    My Feedback http://www.3wheelerworld.com/showthr...ck+shortline10

  6. #6
    Join Date
    Jul 2018
    Location
    TN
    --
    11
    Well, I don't know what kind of Frankenstein set up I have managed to cobble together here, BUT.....I have brakes.

    I pieced this together from the mountain of spare parts I got with the bike. I had to machine a spacer to make it work but I had a set of brand new pads in my boxes of parts that fit.
    All I need is a cable and lever to make it work. That's not a big deal.
    BUT...Here's the rub. It carried a different bolt pattern than my front wheel. I have several spares but I have nothing with this pattern. It measures out to a little over 5 inches so I am guess it's a 130mmx4 pattern? Does that sound right?

    Anyone have a 9 inch front wheel with that pattern they wanna sell? LOL!
    Looks like a 125M or a 185S wheel might work. Anyone know for sure before i spend money?



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    Last edited by Gabriel; 07-13-2018 at 05:16 PM.

  7. #7
    Join Date
    Jul 2018
    Location
    TN
    --
    11
    The more i root around in this thing AND read the manual, it's readily apparent this is NOTHING like original. The ATC200 had a rigid fork system. This one does not so someone has changed the front end out at some point. No crime there but that explains why I don't have the parts to make the front wheel and brakes all jive together. Not a huge deal. I found an 8" wheel on Amazon for less than $40.

    I took it as close to bare frame as I intend to over the weekend and there's been some mods (poorly) done. Pretty lousy welding done to some pretty lousy exhaust hangers. I re-welded them to suit me and spent some time grinding them smooth and smearing a little paint on them. There's not a properly routed anything. No tie straps. I don't really know the PROPER route for the cables and such so I'll just have to get the engine running and then route them the best I can to be out of the way and not bind. I hate zip ties as opposed to the proper aluminum straps but that looks like where I'm headed.

  8. #8
    Join Date
    Jan 2012
    Location
    Carthage NY 250r rules
    --
    2,055
    The 83 atc 200 has a factory front suspension. 82 atc 200 and older came with solid forks.
    250r rules

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