Started the rebuild of my Yamaha YTM 200e. Pics of the tear down.

[Tommy2]

I had posted a week or so back wondering what motor to use (maybe a snowmobile motor?). Anyways, I ended up just deciding I should try to fix up/rebuild the original motor.

Went ahead and stipped it down to a bare frame and started getting the motor apart. Broke a couple bolts on the motor. Had one really stubburn allen head..Even after hitting it with the torch I still broke an allen head on it. Really tough.. Eventually got it.

Need to check the head and block to make sure nothing needs to be milled.

The piston has some scuffs on it.. I'd like to replace it, and re-ring the motor..but I doubt parts are all that easy to find. Mainly I just wanted to get a fresh head gasket on because it was clearly weeping pretty badly.

I may not split the block. Haven't decided yet.

I'll probably go ahead and order a Versah gasket set. I'd like to rebuild the carb, but haven't found a kit yet. If anyone knows of one out there, please let me know.
Will also need a petcock, front end bearings, possibly fork seals.

I'll sandblast the frame and paint it soon. The plastics are all pretty rough, I'll worry about those later. I'll probably sodablast the motor and paint it. Will probably glass bead blast the head and put new seals in it.

The wiring is also a bit hacked up.. Shouldn't be too hard get figured out though.

Any opinions or advice on the project are appreciated.



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[Yamaha_Rules69]

You can still get the piston kit, valves, seals, cam chain, etc. new. Check ebay, or denniskirk.com , or rockymountainatv.com they should all have the parts you need. Im also rebuilding a "low hour of use" 83 YTM 200, chain model that sat for 15+ years (it sat more than it was ever used, which is deffinatly not a good thing). Good luck with the build, and if you have questions along the way, dont be afraid to ask!

[buck]

I remember seeing your original thread about this with the pics. Unfortunately I'm not replying to help out with any technical advice or any other constructive input. I'm just offering words of encouragement.

My first trike was an 84 200E. I was SO mad at my Dad for not letting me have the 225 with the rear suspension. I felt cheated in life forever due to this. I can tell you that I have hundreds upon hundreds of hours of memories from that machine. I spared that thing no love when it came to riding it. I thrashed it, jumped it, submerged it in water, worked it on the farm, sunk it in mud, ice, snow, you name it. The only time I put anything into it when it came to maintenance was when it needed gas. I can honestly say I don't think the oil got changed on it more than three times at the most. I remember having to have the front bearing replaced a couple of times, but that was about it when it came to any mechanical issue. I would get my new 3 wheeler mag and spend an entire evening reading it just to go out the next day and try everything I had just seen in the mag. Needless to say this machine wasn't built to do what I was seeing in the mags. Didn't bother me. I wanted to race anyone I could find and jump anything I could on it.

It never let me down one time. There's absolutely no reason it should have made it as long as it did. We parked it in the barn when I got older and more preoccupied with high school. It sat there for about ten years or so. At the time I was working weekends at our local motorcycle shop helping out at the parts counter. A customer came in looking for some parts for a 200E. I commented that we had an old one in our barn. He ended up giving Dad $100 for it. I found out later that he was able to get it running with little effort. I was quick to let him know it REALLY needed to be looked over given it's neglect while we owned it.

To be honest, I feel this machine made me the rider I am today. When I got to the point where I was old enough to purchase my own ATV quads were the only thing available. I couldn't believe how nice the suspension was on my Banshee and how unbelievably easy it was to ride compared to what I learned on. Every corner and jump took more effort on my trike than someone riding a sport bike. When I was able to make the transition and have access to more properly equipped machines I couldn't believe how easy they were to ride. I still to this day put far more body english into a turn than most of the riders I ride with or race against on my YFZ450. Old habits die hard I guess.

Good luck with the build. I look forward to the pics and progress.

Buck

[Tommy2]

Thanks for the replies. I love reading stories like that. I really wish this was a 225DX for the suspension as well, but maybe I can somehow spring the seat to help out a little. I had a mini bike as a kid with no shocks..Man, that would KILL your back if you rode it for more than 10 minutes. Being that I'm not a kid anymore, I doubt my back can take quite as much abuse.

I'll look into the piston kit and other parts. The cam chain looks good, I don't think it's over stretched. Do you think I should split the block and fully go through the motor? I hate to do things twice, so I want to make sure I get it perfect the first time, but don't want to have a million gears taken apart sitting all over the garage for no reason - and then have trouble remembering how to get it all back together.

I'm also really struggling to find a rebuild kit for the carb. That's pretty frustrating because that should be the easiest part of this whole project - and without a good, solid carb, this is all pretty pointless.

I only paid $50 for the machine. So I'm ok with sinking a couple hundred into it. Hopefully I'll have no more than $300 into it when done.

[Tommy2]

Ended up grabbing this set. Didn't want to go any lower quality than Vesrah.

$40 for the complete kit was about $20 less than I could find anywhere else.

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=310198403333&viewitem=&sspagename=STRK%3AMEWNX%3AIT
I assume/hope it comes with the valve seals.

Also found pistons/rings on ebay. Will see if I can find a good deal on them.. The cylinder walls look pretty good, so I shouldn't have to bore them. Might be a good idea to give them a closer look to see how in spec they are / out of round, etc.. before ordering the std size.

[Yamaha_Rules69]

If the cylinder is still in spec, and you install a new piston and rings, you would be best off to hone the cylinder so the new rings can seat. I wouldnt think the bottom end of the motor would have to be dis-assembled if you cant see or feel anything out of the ordinary. A quick test to do after the jug is off is to grab the connecting rod, and see if it had any play up and down. If it does, it needs a new rod and bearring (you especially see this on 2 strokes, but not nearly as often on 4 strokes). A little play side to side is normal. You could also rotate the crank, roll it and make sure it is smooth, and no binds/sticky spots. If these tests check out, I would say the bottom end should be fine. The other thing you can look at is the oil filter - see if it has any metal in it, and you could also take off the right side clutch cover, and inspect the clutches, springs, etc. Check the manual for the correct specs, and you should be able to measure nearly everything with a dial caliper. Good luck!

[Tommy2]

Thanks. Yea, the clutch cover wil definitely come off and I'll check it all out.

The piston has a pretty bad scuff/rip in one part. Its probably "good enough" for good compression, but if I can find another piston/ring kit for cheap enough - I'll do it. Connecting rod seemed good (crank/bearings felt tight). I'll triple check it and likely leave the lower end alone.

[takeuchitb007]

another person fixing up a 200e, looking good.. I actually just started rebuilding my 200e a week ago or so.. Ordered new rear axle bearings, front brakes, rear brakes, timing chain, timing chain adjuster, .030 piston kit, Gaskets, clutch kit etc the bearings in the diff were excellent so I didnt change them.

It ran pretty good before I tore it down but she has lots of blowby, cylinder compression is low so it's time for a top end..

good luck with your project, we could probably help each other out along the way.

[Tommy2]

Good to know. Keep all your progress updated.
I'm hoping to not touch the rear end. All feels pretty tight.

Where did you get the piston kit? How much is a machine shop going to charge you to bore out the cylinder jug? Where did you order the other stuff as well?

I gotta get new bearings for my triple trees as well.. They pretty well fell apart when I took them off. Gotta remember to order those as well.

Hopefully I can get away without getting a new clutch and cam chain. Don't want to dump too much $$ into this. Hate that I have to order a piston, but probably should.


Oh, and did you find a carb kit? That's the biggest missing piece to my puzzle..

[takeuchitb007]

I got my parts off ebay from a store called The 3 and 4 Wheeler Shop, bikerchickltd is the ebay user.

As for the carb, I didnt buy a kit.. I just took it apart and cleaned it properly.. Let it soak in a good carb cleaner.. I then blew out all the passaged using 250psi of nitrogen.. It's nice to have nitrogen for this kind of stuff.. I work in HVAC so I have it on my service vehicle.. The needle and seat looked fine, theres not much else to rebuild, it's mainly cleaning... just make sure your float bowl gasket doesn't rip when you take it off..

To bore the cylinder it's roughly $80-100 bucks.. All the valve job I'll do myself.. It's really not a big deal... If you plan on keeping the trike it's worth sinking some cash into so you know it's done right.. Really this stuff isn't all that expensive.. My motocross bikes are far more expensive to rebuild so this trike stuff seems like nothing..

Have any sources for good used parts like primary clutches? I think i'm going to need one.. I took a spare engine apart this morning but the clutch is badly grooved..

[Yamaha_Rules69]

Around here I can get a 4 cycle cylinder bored for 30-40 dollars. A 2 cycle is a little more, becuase they have to chamfer the ports. If you just need a hone, it would be even cheaper.

[Tommy2]

My carb looks like it was leaking gas. Pretty much anything exposed to gas for 25 years is gonna be in pretty rough shape. Finding o-rings that are the exact right size may prove difficult. Guess I'll just have order each part separately from Yamaha.
It's frustrating because I bet theres a kit out there that's close enough to work.. I just don't want to gamble on it..