1983 ATC200X basket case resto-mod

[1stGEN110]

I might be wrong on this but I think you can use a 250x/300ex rear axle if yours is bent. This could save you some $ if it will fit the 200X. Hopefully someone on here that has tried this will chime in and confirm this or correct me on it.

Good lead! I’ll do some digging and see what I can come up with on this, thanks!

[1stGEN110]

Still waiting to hear back on the 85’ 200X engine. I did order a DG grab bar today so I can fab up the missing tubes on my subframe. Does anyone know if I can buy DG wheels to fit my stock 200X rear hubs? I’m guessing no one makes a new aluminum front wheel for the 200X?

[Footy]

Still waiting to hear back on the 85’ 200X engine. I did order a DG grab bar today so I can fab up the missing tubes on my subframe. Does anyone know if I can buy DG wheels to fit my stock 200X rear hubs? I’m guessing no one makes a new aluminum front wheel for the 200X?

I am not sure that I have seen DG wheels. I would guess that there would be sources for an 8 inch aluminum wheels with 4 on 110mm bolt pattern. I have some for sale but these are steel instead of aluminum. Most of us use trx300ex or 400ex rear hubs and wheels. Unfortunately this trick does not work for the 250R or 350X.

[1stGEN110]

I am not sure that I have seen DG wheels. I would guess that there would be sources for an 8 inch aluminum wheels with 4 on 110mm bolt pattern. I have some for sale but these are steel instead of aluminum. Most of us use trx300ex or 400ex rear hubs and wheels. Unfortunately this trick does not work for the 250R or 350X.

You are correct I meant Douglas wheels. Sorry!

[1stGEN110]

Looks like the 82’ ATC250R axle is a direct swap on the 200X. You have to buy a sprocket for the R axle as it’s all rigid on the R, not rubber bushed like it is on the factory X axle. I’m probably going to close my eyes when I click the order button and get a Dura Blue. I’m building this bike to keep, and I want it right.

What are you guys opinion on the Kenda front max tire vs the Kenda K530 Pathfinder? Either would probably be fine, I’m thinking cornering would be better with the front max but braking would likely be better with the K530. Pretty sure I can get the front max in a 23.5” for stock geometry but the K530 is available in a 23” so not much of a difference to me there. Thanks!

[350for350]

Yes you can order 8" rims for the back of your 200x from either Douglas or ITP. There may be others, but those are the most common by far. I just ordered a pair of Douglas rims back in June for my 250SX. I have some stock 200X rims on there right now. I gave $160 for them on Ebay. Personally, I prefer the Front Max over any drive tires for the front. It's only my opinion, but I think that tires that are obviously drive tires look stupid on the front of a trike. The pathfinders are good rear tires. They do get pretty good traction for all around (not mud specific) tires.

[1stGEN110]

Yes you can order 8" rims for the back of your 200x from either Douglas or ITP. There may be others, but those are the most common by far. I just ordered a pair of Douglas rims back in June for my 250SX. I have some stock 200X rims on there right now. I gave $160 for them on Ebay. Personally, I prefer the Front Max over any drive tires for the front. It's only my opinion, but I think that tires that are obviously drive tires look stupid on the front of a trike. The pathfinders are good rear tires. They do get pretty good traction for all around (not mud specific) tires.

More great insight, I personally prefer the look of the front max and agree that it looks like a front tire for a trike. Thanks for the input!

[Dirtcrasher]

If you need any, I've got NOS kickstart gears and the updated spring for either the 83 or the 84/85 200X.

[1stGEN110]

If you need any, I've got NOS kickstart gears and the updated spring for either the 83 or the 84/85 200X.

PM sent! Thanks!

I have a shop day scheduled for tomorrow, so after I change the final drive oil in the Gold Wing and address the unfriendly top end noise on my KLX351 it’ll be time to try to split the case on the 200X motor.

[1stGEN110]

Well, I got a lot done on the 200X today. I pulled everything off the clutch side that is needed to split the cases. With that said it didn’t come easy, the oil slinger and clutch were easy. The two JIS countersunk screws that secured the oil pump to the block were insanely tight. I shattered a 1/2” impact rated JIS bit trying to get them out. In the end I had to drill them out which wasn’t too bad. Now that everything is off the clutch side, including the case half bolts, I tried gently tapping the crank snout (clutch side) to split the cases. My rubber mallet didn’t even phase the cases. They are on there really well!

I don’t have a puller yet for the flywheel but I’ll likely order it along with a case splitter tool.

Not that I wanted more of a flight but it’s almost insulting when the remaining studs (the ones I had to drill the heads off) unthread from the block with my fingers…

I also found some puzzling marks on the inner clutch side case half. It appears that the rivets on the clutch basket are somewhat sheared, there are corresponding marks on the inner case half that match the clutch river marks. I also think I have a few shifter parts that are just outright missing. More to dig into when I get the cases apart, maybe the missing shifter parts got wedged behind the clutch basket and the case half causing the score marks? It seems impossible for the basket to contact the case if the bearings are OK and the clutch nut is tight, which both were.

[1stGEN110]

Based off the apparent condition of my engine, and the scarcity/cost of some parts I opted to source a donor bike for this project. I have no idea what kind of shape my CDI, Stator or wiring harness are in. Considering that the trigger coil and cam bearing are both destroyed I think that is the most cost effective way to complete this bike, and maintain it going forward. I picked up this 03’ CRF230 today to cannibalize for the ATC! The modest increase in weight from the starter and wiring should be offset by the slight bump in power from the longer stroke of the 230. The bike runs great and shifts nicely, I was surprised to see a top speed of 58mph on my GPS from the 230. I also want to make a custom LED headlight set up for this bike and having a DC charging system will make that much easier, it already has a Li-ion battery that’s super lightweight so I don’t think It’ll weigh the 200X down too much. As an added bonus, I plan to use the master cylinder off the CRF for my front master on the ATC and I may use the front caliper off the CRF on the ATC as well.

My grab bar should be here Wednesday and I can begin making repairs to the subframe, my goal is to have this bike done by first snow which in NC is usually in January. The timeline is looking good!

Tomorrow I’ll disassemble the rear end and address straightness of the axle.

[1stGEN110]

I will have to sort out the carburetion of this bike to use this motor. I may end up using an XR200 intake and carb as others have, part of me wants to throw a TM33 pumper carb on it but I doubt if there is room. Maybe a custom manifold is in order?

Lastly, I need to do more research to see if my ATC kickstart, transmission and clutch cover will fit on the CRF motor. I’m really torn on that decision. Most guys in the know say the 230 trans is stronger than the XR200 6 speeds due to the lack of kickstart and associated gears that take up real estate in the transmission resulting in thinner gears on the XR.

Even if I cannot use the kickstart gears or ATC 5 speed I’d still like to mount the ATC clutch cover to support the stock rear brake lever. I need to do more research to verify compatibility.

More to come, stay tuned!

[1stGEN110]

Axle is apart, pretty sure its bent but I need some V blocks and a dial indicator to be sure. I'm working on getting access to those tools.

Fitting the ATC clutch cover on the CRF looks like a no-go, visually speaking it doesn't even look close. Looks like I'll keep a fresh battery in it at all times!

I'm looking at plastics and I see Maier and KTXPro sells a set for the 200X. I know and trust the Maier name, never heard of KTX. Any opinions?

[oldskool83]

You can not put a 300ex axle in a stock 200x carrier 83-85. If you build a new carrier or buy my weld on extensions you can. There's a metric fuckton of math involved. Here's built extended correctly +2 semi professional oem swinger. Everything was laser cut and premachined to go together like a puzzle.

Hreatv.com has my specs to offer these to the masses out of round tubing.

It's worth the upgrade, but your chain won't line up and you need special spacers. I did all the engineering and 3D files and 2D drawings of all my parts.

[1stGEN110]

You can not put a 300ex axle in a stock 200x carrier 83-85. If you build a new carrier or buy my weld on extensions you can. There's a metric fuckton of math involved. Here's built extended correctly +2 semi professional oem swinger. Everything was laser cut and premachined to go together like a puzzle.

Hreatv.com has my specs to offer these to the masses out of round tubing.

It's worth the upgrade, but your chain won't line up and you need special spacers. I did all the engineering and 3D files and 2D drawings of all my parts.

Cool, do you have a ballpark cost for this set up?