How Much to Reassemble a Motor?

[Popeye]

I'm about to have my 81 ATC 200 finished (not restored- just complete and running great) and am getting ready to start back up on my 84 250r. I've got 300 head that I will get taken care of locally, but the bottom end is basically no go good other than the casings. I'm working on acquiring all of the motor parts. How much would somebody charge to put the bottom end together for me? The local shop (the only one that will touch a trike) quoted me at like $70 an hour and said it will take at least 8-10 hours, maybe more. That's around $700 plus. I could buy a running motor for less than that. Is that aboutthe going rate for this job or can some of ya'll folks do it cheaper? I realize shipping may be a problem. I'm gonna check into that. Hoping for a flat rate box, but I ain't counting on it. I've got to explore my options on that. Anyways, just trying to get an idea of what this will cost.

Thanks for any input.

[atc007]

Disassembling,cleaning,evaluating and reassembling a R bottom= about 5 hours. A good tech will run ya $45-$70,,but those guys are ripping people off,unless they saw yours and it's cobbled up w american bolts etc.. Hard to say without pics. You say all but the cases are bad? If you need a tranny,,or even all bearings and seals for that matter. I'd look for a good low end. I have a cpl I think. Shipping is costly though.

[Popeye]

Yea, I think the casings are about all mine may be good for. I'm in the process of tearing it down now. Haven't broken it open yet. I thinkthe bolt that holds the clutch basket on is stripped. What is the typical socket size? I tried a 1-1/16, everything else is either too big or too small. I think the manual says a 27mm if I read it right. But that don't make sense to me, cuz this 1-1/16 fit then stripped it out I think. If I could just get that basket off then I could inspect the tranny. The motor is full of sludge (it comes up with the rod). It sat outside with no side casings, but the head was on it. I was thinking I could get it apart and then soak everything and then see what I got.

ATC007- I am sending you a PM.

[Scootertrash]

The stealerships up here in MN are running at 90-95 an hour for labor. My machine shop guy charges 250.00 for bottom end labor (his shop rate is 75.00/hr), then you'd have to throw parts into that. My rate is a little cheaper than that, but I have machines stacked up like cord wood to work on so I have no time. The situation you have there, well, ya never know what you're going to find once you get her cleaned up.

[Popeye]

Yea, I was thinking soak everything in oil or something and then post pics of all the gears and what not to get opinions on what is good and what ain't. I'm probably in the market for a bottom-end, but it will be a bit before I can get it. I would love to hear from folks who have one. I'd prefer a bolt on ready one, but I'd be interested in anything. If I can get one cheap I might be alright between the two I would have.

[Dirtcrasher]

Disassembling,cleaning,evaluating and reassembling a R bottom= about 5 hours. A good tech will run ya $45-$70,,but those guys are ripping people off,unless they saw yours and it's cobbled up w american bolts etc.. Hard to say without pics. You say all but the cases are bad? If you need a tranny,,or even all bearings and seals for that matter. I'd look for a good low end. I have a cpl I think. Shipping is costly though.

Bill, you know I luv ya!! But thats like 10 to 15$ an hour. Maybe there are some good techs at that cost but I won't lift a finger unless I'm in the 25-35$ an hour. I'm too particular, it's taken me years to learn these motors and I still by no means consider myself an "expert". I just do the best I can....

But, I do my best and warranty everything unless they have a jetting issue....

[Popeye]

I took it as $45-$70 an hour. But I'm usually wrong when it comes to just about everything lol.

[Dirtcrasher]

I took it as $45-$70 an hour. But I'm usually wrong when it comes to just about everything lol.

Nope, your right. Any dealer will charge you those rates. Some garage guys can do as well or better a job than a dealer and save you some bucks.

[ATC-Eric]

I used to charge around $100 to go through a smoker bottom end. Thats probably also why we went out of business lol. And that was also OUT of the frame.

[atc007]

Bill, you know I luv ya!! But thats like 10 to 15$ an hour. Maybe there are some good techs at that cost but I won't lift a finger unless I'm in the 25-35$ an hour. I'm too particular, it's taken me years to learn these motors and I still by no means consider myself an "expert". I just do the best I can....

But, I do my best and warranty everything unless they have a jetting issue....


Ohh,same here,, I am absolutely anal. But<if I can't go flat rate,I'm not doing my job. : ) Obviously,not everyone should be held to those standards. But I hold my self to flat rate. if Billy Bobs doing it for a case of beer. You MAY get a perfect job! BUT,,,,,,You MAY not.......lol.. WHich always ends up costing more in the long run than it would have cost up front.. But I Totally here you DC. It's just because I'm a shop. Same as your machine work! I know that is top notch!

[stroberts22]

Download a manual for free and do the work yourself. It's not rocket surgery. If you want something done right do it yourself and save alot of money. Anytime I ever paid anyone else to do a job I seen I could do it just as well or even better than they did with the exception of port work. They are just doing it for the money and are going to do it the fastest and cheapest way to get you out the door and your money in there pockets. Alot of the stuff that I work on I couldn't afford to pay a person the time it takes to do it. You will be amazed how easy it is and if it ever have problems you won't be intiminated to tear into it and fix it.

[atc007]

Download a manual for free and do the work yourself. It's not rocket surgery. If you want something done right do it yourself and save alot of money. Anytime I ever paid anyone else to do a job I seen I could do it just as well or even better than they did with the exception of port work. They are just doing it for the money and are going to do it the fastest and cheapest way to get you out the door and your money in there pockets. Alot of the stuff that I work on I couldn't afford to pay a person the time it takes to do it. You will be amazed how easy it is and if it ever have problems you won't be intiminated to tear into it and fix it.


While I agree .. And would love to see everyone try.. A Ruined crankshaft , water pump,etc..because the thread was left hand. Won't shift because the forks aren't in right. Or because the pawls are in backwards.. The things that can and do go wrong,COST,,Time and money.. There is great satisfaction in doing it yourself ,,sure,,it's the American way,,well used to be.. But I have seen TENS of thousands of dollars parts ruined over the years by do it yourselfers,,JMHO>

[Popeye]

Download a manual for free and do the work yourself. It's not rocket surgery. If you want something done right do it yourself and save alot of money. Anytime I ever paid anyone else to do a job I seen I could do it just as well or even better than they did with the exception of port work. They are just doing it for the money and are going to do it the fastest and cheapest way to get you out the door and your money in there pockets. Alot of the stuff that I work on I couldn't afford to pay a person the time it takes to do it. You will be amazed how easy it is and if it ever have problems you won't be intiminated to tear into it and fix it.

I agree with what your saying, but I also know enough to know that I'm not ready to build a motor from the ground up. I've put in clutches, rebuilt top-ends, and done a few other minor jobs, but I just don't have the confidence yet. If I could watch it done a time or two I have no doubt I could do it well enough. With all that said- I've never touched a 2-stroke. Heard they were simpler, but I'm just not ready yet.

[Yamaha_Rules69]

Those old air cooled motors are about the easiest to work on. I agree with most of the above, get a service manual, and follow the steps, and dont skip a step. I went to college for powersports, and this is what I learned. As long as you follow the guidelineds (especially if its your first time) you will have no worries, I promise. I have torn a few apart before, and brought them to a shop to have the new crank bearings and crank installed, and it was 30 dollars each time, and have not yet had an issue. Most all the other bearings will come out easily, so whatever you can do yourself the better. Dont bring the whole motor to a shop, you'll get ripped off. I have worked at several shops, and know how it is. If you want to ride a 3 wheeler, you got to know how to turn a wrench, no questions asked. I would start by getting the correct socket - 27mm you say, NOT STANDARD, and use an impact wrench for that clutch nut - and no other nut besides flywheel on this motor. If you have questions, take a few pics, and the boys and I here will definatly help you along the way.

[userj8670]

Hey man, I just did my clutch on my 250sx and mind you i have never torn into a trike motor before. I was a little nervous but honestly, I followed the manual step by step and everything turned out right. There were a few parts i was a little unsure of but i just sat down and reread the manual and it eventually made sense. It def looked intimidating but once you get going it honestly isnt that bad at all.

[zzmegad]

1-1/16" = 26.9875MM

I know its wrong, but in this case would work fine (actually better) if it fits the nut.

[atc007]

Bill, you know I luv ya!! But thats like 10 to 15$ an hour. Maybe there are some good techs at that cost but I won't lift a finger unless I'm in the 25-35$ an hour. I'm too particular, it's taken me years to learn these motors and I still by no means consider myself an "expert". I just do the best I can....

But, I do my best and warranty everything unless they have a jetting issue....


LOL,,I see my mistake! I meant $45-$70 PER HOUR !!! Not for the job! I see what you meant DC.

[atc300r]

Shipping alone would be about $200.give or take. Youd have shipping both ways.Iv seen lower ends on ebay that cheap.I agree with these guys get the manual and go from there.I started doing my own mechanics years ago .Like some of the guys here stated cost and workmanship.I cant see paying someone to do something I can do myself.I do 99% of the mechanics on my vehicles as well.If you can do a topend thats half the battle right there.If you get in a jam just post on here and we will help you out.Thats the beauty of the internet we can be right there with you.Good Luck.

[Popeye]

I appreciate everybody's willingness to help. I just got back from New Orleans and I am gonna get back to tearing the motor apart tomorrow. Should be able to see what I got soon. I think it's gonna be shot though. I also have a lead on a nice bottom-end, so we'll see.

Thanks for all ya'lls generosity and input.

Edit: I went out there few minutes ago and the 1-1/16 is definitely stripping it out. The 27mm is too big. I've got the sprocket held still,
but I just can't break this nut. I think I'm gonna try to hammer a 1 inch onto it tomorrow. This thing sat outside exposed for years. The head was on it, but the side casings were not. There's so much sludge coming up with the rod it ain't funny. I'm gonna continue tearing it down, just to get a look at it. But I think I would spend more on parts then I would on a good used bottom-end. Any advice for getting the stripped nut off would be greatly appreciated.

[zzmegad]

get the right socket, soak some penetrating oil in the threads, heat the nut with propane torch, impact will work best

[Yamaha_Rules69]

The only thing about buying a used bottom end, is that you never know what was all done to it, or if there is something seriously wrong with it. If you tear the bottom end down, and replace what needs it, you will have a reliable engine that will last you for years to come.