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Thread: Barnboy's 1984 ATC200M Rebuild

  1. #1
    BarnBoy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Barnboy's 1984 ATC200M Rebuild

    Hi all,

    I have a 1984 Honda ATC200M I am going to be rebuilding. This bike has been in my family since new, and was used on the family farm for years. I got it in the winter of 2014, got it running again and drove it around the farm for the next year or so. Ended up moving, and didnt have a place to ride or truck to haul it anywhere so it pretty much sat in the garage from early 2016-now. I got it out every couple months, drove it around the street. Put a clutch in it in the summer of 2017 because it needed one bad.

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    Reason for the rebuild is because it smokes and burns a fair bit of oil, also there is a ticking noise in the top end. And I have found metal shavings in the oil whenever I have changed it, so theres something in there that needs looked at. Also may end up splitting the cases and replacing the countershaft, but not sure on that yet.

    First step was to check compression. Cold, not having been started since last spring compression was 135 psi. I think that's because of the oil that was in there. When I fired it up it fogged the whole neighborhood lol. But when I checked compression warm it was @ 125 psi. So not terrible, but not great.

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    Took it on one last ride, then yanked the motor.

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    Will update as I progress. Next step is to clean the crud off the engine.
    1984 HONDA ATC200M

    Da velder

  2. #2
    Join Date
    Jul 2009
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    South Florida
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    Metal shavings could be a loose timing chain and the excessive noise your hearing , I’ve seen them so loose that they rub on the inner cases .
    Timing chain is not self adjusting, you must loosen the 14mm nut at the lower left side of the cylinder while it’s idling and it will tighten , hopefully theirs enough tension left or you will need to replace it .
    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

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  3. #3
    BarnBoy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Quote Originally Posted by shortline10 View Post
    Metal shavings could be a loose timing chain and the excessive noise your hearing , I’ve seen them so loose that they rub on the inner cases .
    Timing chain is not self adjusting, you must loosen the 14mm nut at the lower left side of the cylinder while it’s idling and it will tighten , hopefully theirs enough tension left or you will need to replace it .
    That could be it. I'm hoping that's the case. But some of them are magnetic so???

    I've tried adjusting it, I might have a stretched chain as it didnt make a big difference. Planning on replacing the chain anyway when I'm in there. Original is 30+ yrs old.

    Thanks
    1984 HONDA ATC200M

    Da velder

  4. #4
    BarnBoy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Any tips on cleaning all the gunk off the engine? I got 2 cans of engine degreaser, I guess it needs to be rinsed off so I'll have to be careful about not getting water all in the engine.
    1984 HONDA ATC200M

    Da velder

  5. #5
    Join Date
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    South Florida
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    I use formula 88 for the pre wash and mineral spirits as the secondary cleaning of the outside and inside parts .
    Last edited by shortline10; 01-29-2019 at 03:59 PM.
    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
    BarnBoy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Oklahoma
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    Ok, thanks. I'll probably just use this degreaser and rinse off with a hose this weekend once the temps get a bit above freezing.
    1984 HONDA ATC200M

    Da velder

  7. #7
    BarnBoy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Well, got some time to clean the engine this morning. Didn't end up using the degreaser. I used an old tooth brush, little wire brush, steel wool, and a wire wheel on a cordless drill. That and some hot soapy water and carb cleaner did a pretty good job of cleaning it. Hard to get into all the corners but the majority of the gunk is off. Don't want that falling in my engine. Inspected cases and they look good, can't find any cracks. A bit of minor pitting on the bottom, but should be fine.

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    1984 HONDA ATC200M

    Da velder

  8. #8
    BarnBoy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Anyone have experience with Winderosa oil seal kits? Found one, says it fits the '84 200S. I'm thinking it should fit my ATC200M just fine, correct? Would it be better to buy OEM seals or will these work fine?

    https://www.mfgsupply.com/822341.html
    1984 HONDA ATC200M

    Da velder

  9. #9
    BarnBoy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Oklahoma
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    Finally was able to start working on it today. Got the pulse generator off. One of the e clips for the weights was off and laying on the bottom of the cover. Still ran fine though. Here's a few pics. Hoping to document the whole process, partly to help myself on reassembly, but I hope it will also be a help for other people who are doing this.

    Good clean work area and lots of plastic bags are a must Click image for larger version. 

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    Impact screwdriver helps a lot with safely removing Phillips head screws.
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    Helps to mark pulse generator for reference.
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    1984 HONDA ATC200M

    Da velder

  10. #10
    Join Date
    Jun 2010
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    House Springs MO
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    I glanced over the OP's name and thought I'd seen a ghost.

    Sent from my SM-G960U using Tapatalk

  11. #11
    BarnBoy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Quote Originally Posted by bkm View Post
    I glanced over the OP's name and thought I'd seen a ghost.

    Sent from my SM-G960U using Tapatalk
    ??????????
    1984 HONDA ATC200M

    Da velder

  12. #12
    BarnBoy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Oklahoma
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    Pulled the cam today. Small right side journals and lobes were worn but within spec. Right side journals however, are not so great. Cam journal is 0.003" below spec, and head journal is just barely below spec. Clearance is specified @ 0.003", but according to my calculations I have 0.009" clearance between the cam and journals. Bummer. Fair bit of play on the cam when installed too. And some minor scoring on the bearing surfaces.

    Looks like I'll be needing a new cam, and will probably have to do something with the head too. I have a complete head off a 185S in the shed that I might be able to use if it will interchange. Have to check and see if it's any good. Gonna check and see, but maybe a new cam might close up that clearance a bit??? Probably not enough though.

    Is there any easy fix for this other than a new head?

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    1984 HONDA ATC200M

    Da velder

  13. #13
    Join Date
    Jun 2010
    Location
    House Springs MO
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    Quote Originally Posted by BarnBoy View Post
    ??????????
    Your screen name is similar to another member who has risen from the grave.

    Sent from my SM-G960U using Tapatalk

  14. #14
    BarnBoy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
    Join Date
    Jun 2015
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    Oklahoma
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    Quote Originally Posted by bkm View Post
    Your screen name is similar to another member who has risen from the grave.

    Sent from my SM-G960U using Tapatalk
    Ahh I see.

    Got my case splitter arms from the machine shop. Tacked a nut on there and I'm ready to go. Sure beats spending $60 on the Tusk one.
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    1984 HONDA ATC200M

    Da velder

  15. #15
    BarnBoy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
    Join Date
    Jun 2015
    Location
    Oklahoma
    --
    305
    Also got the whole top end off the motor.
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    As soon as I pulled the head oil started running out of the combustion chamber! Gasket was definitely compromised, I knew that from the leakage onto the cooling fins. It also appears to have an OEM .50mm oversize piston in it. Looked surprisingly clean too. Not sure how much slop there's supposed to be in the bore, but it had a bit.

    Rod appears to be good. I can feel some side to side play which is normal, but cant feel any up/down play. Small end may be worn a bit, but appears to mic according to the "new" spec. Pin was miced and shows its on the lower end of spec. Tried an almost new spare pin I have and it tightens things up nicely.

    All in all it doesent look terrible, theres nothing that jumps out at me. I knew it had been rebuild, but not to what extent. All my grandfather said was some guy rebuilt it and it cost a lot lol. I guess the guy may not have been a hack who did the work, as he used an OEM piston, and had it bored. Didnt just slap new rings on it.

    Curious why it was bored to the 2nd oversize though?? If I have to bore again I will be at 3rd oversize.
    Last edited by BarnBoy; 02-09-2019 at 10:25 PM.
    1984 HONDA ATC200M

    Da velder

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