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Thread: Barnboy's 1984 ATC200M Rebuild

  1. #31
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
    Join Date
    Jun 2015
    Location
    Oklahoma
    --
    731
    Got then cases split tonight. Like an idiot I forgot that the centrifugal clutch was LEFT HAND thread, so when using my impact to remove it tighted a bit and then wouldn't budge. Tried it again, just using my hands to hold the clutch drum, and it kept slipping. THEN I realized it was left hand thread, and buzzed it off. Didn't sit there an on it all that long, but it got pretty tight. I'm really hoping I didn't screw up the threads. They look maybe a tad stretched but not that bad.

    Also, both of the Phillips head screws for the oil pump are stripped. I was expecting this, and used a impact driver, but they are stuck really good. I do want to inspect the oil pump....but idk if they use a sealant on the threads? Anyone ever have to drill them out?

    Case splitter worked good, but manual didn't mention that one bolt that comes in from the right side. So I couldn't figure out why only one side was separating. Found the bolt and it split perfect. Was careful with the splitter, so I don't think I did any damage.
    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  2. #32
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
    Join Date
    Jun 2015
    Location
    Oklahoma
    --
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    Can see where timing chain was rubbing on case too.
    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  3. #33
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
    Join Date
    Jun 2015
    Location
    Oklahoma
    --
    731
    Anyone have any tips on what works to remove stuck/stripped oil pump screws?

    Also whats the best way to replace the case bearings? Heat in oven? If so what temp? Puller? Any tips appreciated.

    Also noticed this spot near the crank bearing. Looks to me like it was machined this way, but just curious if thats normal? Had a small amount of side to side play with the bearings sliding in the case housing before disassembly. But didn't notice any rubbing. Is crank supposed to have in/out play when installed?

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    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  4. #34
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
    Join Date
    Jun 2015
    Location
    Oklahoma
    --
    731
    Oil pump screws were stripped, so drilled them out with a left hand drill bit. Worked like a charm. Busy cleaning/scraping gaskets on the cases.

    Also found a local Harley mechanic who can bore and hone the cylinder for $60. Once I get a piston that's what I'll do.

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    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  5. #35
    Join Date
    Jul 2018
    Location
    TN
    --
    1,065
    Doin good bro. Keep it up.

    A 200M engine is next on my build list. .....soon as I can find a 200m engine that is. Lol!
    I have plans for a 200m engine.
    I was born and raised on Venus & I may be here a while.....

  6. #36
    Join Date
    May 2006
    Location
    The Open Road
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    4,729
    Damn. This thing ain't going down without a fight.

    I admire your perseverance

    Sent from my Z958 using Tapatalk

  7. #37
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
    Join Date
    Jun 2015
    Location
    Oklahoma
    --
    731
    Thanks fellas. This forum is a big help. The goal is to end up with a pretty much brand new motor (or close to it...replacing everything that not within spec), all new bearings. I replaced clutch not long ago so that's new too.

    Gonna get a gal or 3 of diesel fuel to wash the grime off the cases I think.
    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  8. #38
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
    Join Date
    Jun 2015
    Location
    Oklahoma
    --
    731
    Been chipping away at this project. Getting parts ordered, cases cleaned, and everything miced. Might be ordering a used set of engine cases....not sure yet. Anyway here's some pics, was able to get most stuff OEM. Some was discontinued but thankfully eBay had some.

    For the countershaft pilot bearing I bought a Koyo HK1512, only bearing not OEM....I'm thinking it should work just fine. OEM was NTN HK1512 V2. Not sure why it has the siffix V2 but hopefully they are the same bearing.

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    Also head is being milled for bronze cam bearing.

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    Removed left mainshaft bearing from case by setting oven to 275° and waiting till case would boil water drops sprayed on it. Then removed from oven, carried to garage, and a few good taps of the case on the workbench and it was out.

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    Also trying to decide if I want to media blast the cases before reassembly or not. Not sure if I want to take the risk of media still being trapped in there.....but would be nice to get it cleaned up and painted and looking brand new.
    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  9. #39
    Join Date
    Jul 2018
    Location
    TN
    --
    1,065
    Looking good man.
    It takes a loooong time for such a little motor.
    I was born and raised on Venus & I may be here a while.....

  10. #40
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
    Join Date
    Jun 2015
    Location
    Oklahoma
    --
    731
    Well, long time no post but I have been making progress....albeit slowwwww.

    Got all the cases media blasted and a friend's place. Ended up ordering a nice used set of cases off eBay for like $50 that we're in better shape than my originals. Got them all cleaned up, and installed the last of the bearings in the bottom end. Also got the seals in the bottom end too so the cases are all done. Got the countershaft seal a tad underflush accidentally, but hopefully it will be fine.

    Now all I'm waiting on is time, arrgh. Gonna be out of town for a bit, but when I get back I plan to take my crank to a local motorcycle engine builder for bearing replacement. He has the tools and know how, and hopefully it won't cost me too much.

    Then have to get the bottom end reassembled and I can start on the top end. Cylinder bored, timing chain, piston, yada yada yada. Will update as I go.

    Got an old Kawasaki klt250 to beat around on while I get the 200M back together. Except it doesn't run. So yeah. Another project lol

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    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  11. #41
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
    Join Date
    Jun 2015
    Location
    Oklahoma
    --
    731
    Update: got the cases together, transmission assembled etc. Working on reassembling the rest of the bottom end now. Sent the crank to @dirtcrasher for replacing the crank bearings, so the only thing in there I haven't touched is the crank/con rod but it was well within spec.

    Ordered a stock 200X piston in 3rd oversize and it's out to be bored at the shop now.

    So, it's coming together slowly....can't wait till I can ride again.Click image for larger version. 

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    Last edited by BarnBoy; 01-01-2020 at 10:13 PM.
    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  12. #42
    Join Date
    Oct 2002
    Location
    Northeast
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    17,438
    Good deal bud, you're getting there!!
    All our government does is distract us while they steal from us, misspend our tax $ and ruin our country

  13. #43
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
    Join Date
    Jun 2015
    Location
    Oklahoma
    --
    731
    Well I got the left side of the engine all assembled. Cam chain, tensioner, starter gears, etc. Then I installed the cylinder with a flat top 200X Shindy piston. Working on putting the clutches together now. Going together good for the most part, so far. Hopefully I'll get the clutch stuff all buttoned up and I can start on the head.

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    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

  14. #44
    Join Date
    Apr 2019
    Location
    South Dakota
    --
    248
    Sounds like you are finally in the home stretch, i have found with rebuilds that as soon as the cases are back together on that it is smooth sailing till the end. cant wait to see the finished product.
    Currently : trx400fw, ct70, 250es,200x, xl80s, 350x, 350x, 225DX, trx300

  15. #45
    BarnBoy is offline Just Too Addicted Arm chair racerJust too addicted
    Join Date
    Jun 2015
    Location
    Oklahoma
    --
    731
    Quote Originally Posted by Homeless Dave View Post
    Sounds like you are finally in the home stretch, i have found with rebuilds that as soon as the cases are back together on that it is smooth sailing till the end. cant wait to see the finished product.
    Yessir, getting the cases and trans together is kinda the last big hurdle (hopefully lol). Now it's just a matter on cleaning and relubing parts, or installing new ones. My only apprehension is trying to get the centrifugal clutch nut torqued to 80ft lbs on the bench. Once that's done it's time to inspect the head again...lap valves and it'll be ready for paint!

    Doing all this motor work makes me want to strip it down to the frame and get it powder coated and rebuild the chassis but it's been apart too long and I'm itching to ride it haha. Maybe once I get any kinks worked out I can do that.
    1984 HONDA ATC200M - OG, mid-restoration
    1981 HONDA ATC200 - future build
    1981 HONDA ATC185S - parts
    1984 ATC200X - roller, future build
    1984 Honda ATC250r - in a million pieces- ISO grab bar, PM if you have one

    Da velder
    _______________________________________________
    Feedback:
    http://www.3wheelerworld.com/showthr...ck-for-Barnboy

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