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Thread: 1983 ATC200X basket case resto-mod

  1. #1
    Join Date
    Mar 2020
    Location
    NC
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    111

    1983 ATC200X basket case resto-mod

    Today marked day one of my 1983 ATC200X restoration. I started by taking some before pictures. She is quite rough, but mostly intact.


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    Last edited by 1stGEN110; 08-20-2022 at 09:21 PM.
    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

  2. #2
    Join Date
    Mar 2020
    Location
    NC
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    111
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    I bought the bike a little over a month ago for $250. The clutch cover had been unbolted and left loose on the engine. The gas cap and spark plug had also been removed and then the bike was left out in the weather for an unknown amount of time. The CDI pickup looked practically new, the wiring still had color to it which stood out as the rest of the bike is sunbaked. The missing parts are,
    Kick start lever
    Kickstart gear set cover
    One kickstart gear (I found a lone kickstart gear inside the fuel tank….)
    Gas cap
    Clutch cover bolts

    The engine looks OK from the outside and the engine is not locked up. The clutch, oil pump, oil filter slinger thingy and the primary gears look pretty good. No rust amazingly.
    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

  3. #3
    Join Date
    Mar 2020
    Location
    NC
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    111
    The cam has what appears to be a bushing or the remnants of a needle bearing but it is galled and the lobes are pitted and worn. The head luckily appears to be mostly undamaged. I think it is salvageable.

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    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

  4. #4
    Join Date
    Mar 2020
    Location
    NC
    --
    111
    The cylinder looked better than I expected to have had rain water entering in it. The journals in the head could be better but they are smooth. I can thinking about trying to polish them out.

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    Last edited by 1stGEN110; 08-20-2022 at 09:40 PM.
    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

  5. #5
    Join Date
    Mar 2020
    Location
    NC
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    111
    The piston looks pretty good, some minor scratches and the rings were easily unstuck by hand. The cylinder looks great, it measures roughly 2.630” with my dial calipers. The liner looks thinner than I’d expect a stock Honda liner to be.

    The carb appears to be a stock Keihin the main jet is a 118 and the pilot is a stock 40, the carb is in remarkably good condition. The bike has a very rotted Supertrapp pipe.

    I’d love to rebuild the motor with a mild compression piston and perhaps a mild camshaft. Next step is to split the case and see what surprises lurk inside the case halves!? I also found the timing advance spring is missing so I’m wondering if the person who worked on this trike last knew what they were doing. On a brighter note the only bolt that broke is one 8mm bolt that holds the parking brake cable into the rear caliper. Part of the stub is protruding so I’ll have that to play with once I figure out how to get the caliper off!


    If the engine is viable I’ll build it, if not I’ll probably send it to Mark Brenny in Iowa for an exchange.

    Any ideas if this is a high compression piston? I’m thinking it is.

    I welcome any comments, ideas or sympathy!
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    Last edited by 1stGEN110; 08-20-2022 at 09:55 PM.
    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

  6. #6
    Footy's Avatar
    Footy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
    Join Date
    Feb 2015
    Location
    Charlotte, N.C.
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    296
    Good job man! For the parking brake bolt just buy the parking brake block off plate. Less than $15.
    The honda parking brake almost never works and is a bunch of unnecessary weight.
    Looks like a maier front fender for a 250R.
    Put your butt on the inside fender or end up on the ground!

    TRX450ER
    ATC250SX
    ATC350X
    ATC110
    ATC185S
    XR100R
    CRF230F
    Raptor 125
    Breeze 125
    Grizzly700

  7. #7
    Join Date
    Mar 2020
    Location
    NC
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    111
    Thanks for the encouragement! I’m really excited to fix this bike up, I can remember riding my grandpa’s ATC200ES before I rode anything else off road as a kid. I was less than 5 years old and am 30 now, so there’s some nostalgia and really fond memories there.

    I like the look of the front fender! I’ll check out the block off plate, I could make one but for $15 I’ll save the time. The mechanism looks kind of Mickey Mouse, can it be made to work? I’d like to have the parking brake if able.

    My plan for the bike is to make a sporty trail rider. I have a buddy who has a Yamaha Blaster and this will be my go to when he is on that or I’m just fooling around. I plan to finish it in red white and blue somewhat like the 85’-86’ ATC200X.

    Still mulling over fixing this engine or swapping a CRF230f engine, or a Pitster Pro 230cc and slapping a battery on the frame. I would like to keep this classic all Honda if at all possible. Decisions…
    Last edited by 1stGEN110; 08-21-2022 at 06:21 PM.
    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

  8. #8
    Join Date
    Mar 2020
    Location
    NC
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    111
    I had one surprise yesterday as I was taking this bike apart. Behind the headlight I found a small black box. I could tell by its design is was a hall-effect sensor, branded TEC which is a common Honda OEM supplier. The signal wire to this sensor was gone and there was a chip in the plastic of the sensor. I set it aside pondering why I’m the world there would be a pickup coil type sensor anywhere near the headlight. Upon pulling the CDI pickup plate cover off the head and seeing the new pickup coil the whole ordeal made sense. There was 3/8” of play in the end of the camshaft due to the roasted cam bearing, when that bearing failed I’m guessing the advance mechanism/trigger crashed into the CDI pickup plate and killed the original pick up!

    Oh I bet this bike could tell some stories.

    I also like the “Wooly Booger” rear tires.
    Last edited by 1stGEN110; 08-21-2022 at 06:06 PM. Reason: Autocorrect decided to change words to the wrong meaning!
    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

  9. #9
    Join Date
    Mar 2020
    Location
    NC
    --
    111
    I have two questions for those in the know,
    First off, my rear subframe (where the grab bar bolts on) has snapped off. I can fix the tubing and weld in new threaded inserts, who makes the best aluminum grab bar? I know the DG is available and there are a few others around too. What’s the consensus on which aluminum grab bar to get?

    Second, my handlebars are trashed; rusted beyond salvage. Is there a known bend that matches the stock ATC 200 bars relatively well? Preferably in aluminum.
    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

  10. #10
    Join Date
    Mar 2020
    Location
    NC
    --
    111
    Took advantage of my day off today and got some additional work done! The bike had a lot of caked goop all over the cradle of the frame. I also found that the cross bar on the handlebars was slightly rusted! As in rusted in two!

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    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

  11. #11
    Join Date
    Mar 2020
    Location
    NC
    --
    111
    She looks a lot better post pressure washing, it appears that brake fluid has killed the paint on the frame near and below the rear master cylinder reservoir; that allowed the corrosion to accelerate in that area. The pitting is worse there but it doesn’t look as if it’ll affect the structure or integrity of the frame. I received a tremendous blessing today. The infamous swing arm bolt was something I was dreading, the nut came off easy and I resisted the urge to go to town on it with a sledge, instead I liberally applied WD40 and PB blaster to the swingarm bolt and went inside and ate lunch, when I came back outside I gave it a couple good whacks with a rubber mallet and she popped right out! The stripped frame is how she sits now. I need to blast the frame and repair the broken tubing back by where the grab bar mounts then send the frame out for powder coating.

    While I was cleaning the trike I found an alarming amount of runout on the rear wheels. They have some deep gouges in the bead area so I’m not surprised that they are not round. I hope the axle isn’t bent but I wouldn’t be surprised if it were. There is less runout on the front wheels but still way more than I’d expect from the wheel. Next step is to check the wheel bearings.

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    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

  12. #12
    Join Date
    Apr 2014
    Location
    Edmond, KS
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    2,531
    Honestly, if you're this far into it, I wouldn't bother to check the bearings. They would just be replaced. They'll never be easier to get to than they are now.

  13. #13
    Join Date
    Mar 2020
    Location
    NC
    --
    111
    Quote Originally Posted by 350for350 View Post
    Honestly, if you're this far into it, I wouldn't bother to check the bearings. They would just be replaced. They'll never be easier to get to than they are now.

    I agree 100%, every bearing that I can change will be changed. That includes the loose ball bearings in the stem, I’ll change them to tapered roller bearings like a proper bike should have. What I meant was, I hope to find bad bearings causing the runout and not the axle being bent or the wheels. But I think it’s more than bearings personally.

    What usually bends first on these trikes? Wheels, hubs or the axle?
    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

  14. #14
    Footy's Avatar
    Footy is offline At The Back Of The Pack Arm chair racerAt the back of the pack
    Join Date
    Feb 2015
    Location
    Charlotte, N.C.
    --
    296
    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.
    Put your butt on the inside fender or end up on the ground!

    TRX450ER
    ATC250SX
    ATC350X
    ATC110
    ATC185S
    XR100R
    CRF230F
    Raptor 125
    Breeze 125
    Grizzly700

  15. #15
    Join Date
    Mar 2020
    Location
    NC
    --
    111
    I just got an offer on a running 1985 200X motor. It has been worked on and I think it has a dirt bike head as there’s a compression release on the right side of the head. Any reason to stay away from that if I can get it for $750 or less? Im mainly concerned of timing changes between the 85’ and my 83’ CDI and harness? Thanks for the expertise guys!

    I’m going to try to get my motor apart today but I don’t have a case splitter tool or a flywheel puller. I’ll try to open it up from the clutch side case half. If it’s rusted inside I’m a lot more tempted to abandon or at least delay building this original engine.
    1979 ATC110
    1983 ATC200X
    1985 ATC70
    1986 ATC125M

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