1982 Honda ATC 185S Resurrection

[FLynes]

Hi all,

I bought this 1982 Honda ATC 185S off of Craigslist for $100. I know that, to many people, it probably looked like a basket case not worth the time to restore, but I have a soft spot for things that have been neglected and need to be fixed. I introduced myself on this thread: http://www.3wheelerworld.com/showthread.php/155001-Hello-from-San-Angelo-Texas . Since my uncle, who passed away in 2004, had a 1982 ATC 185S, I thought this would be a great way to feel like he was still around.

As long as I have a manual to follow and the right tools, it's hard to screw things up. I did have to order a puller, but I had everything else. I consider fixing this trike good therapy, especially after a long day of instructing young Soldiers.

So far, I've sanded down the frame, forks and rear plastic (still missing the front plastic) and painted everything. I've had great luck with Krylon Fusion, so I chose Red Pepper and did the forks and rear plastic with it; I am very happy with the results. This weekend I stripped the engine down to pieces, degreased everything in my parts washer and then threw the case parts in the dishwasher. A nice coat of Duplicolor Cast Aluminum made everything look great.

My next project is to get a cylinder jug, mike it and hope I can get away with just honing, and get a rebuild kit to put everything back together again. Here are my before and during pics....all comments and suggestions are welcomed.

[shortline10]

Looks great !!

[Worden18]

Very cool. It's nice to see someone take the time to bring it back to life. Enjoy the journey! Keep us updated

[Big G]

That engine paint almost looks bang on! Are you going to do the wheels the same color?

[dustrunner]

great job...keep up the good work....

[FLynes]

That engine paint almost looks bang on! Are you going to do the wheels the same color?

I actually bought some Duplicolor Stainless Steel and painted the drum brake side of the front wheel. I like the way it turned out, so I think I'm going to stick with that, just to give it a hint of contrast. I have been very pleased with Duplicolor products, as well as the Krylon Fusion paints. Preparation is the key to getting the paint to adhere properly.

[Keepah Rolln]

Looking good. I also have a 1982 185 that I am getting ready to tackle this spring..I got mine for free and its in alot worse shape..

[FLynes]

Scuffed the rear wheels with my drill this evening and hit them with the Duplicolor Stainless Steel. I know I oversprayed onto the tires, but they're getting replaced, so it doesn't bother me. Tomorrow, I'll take the footpegs off and spray them with Duplicolor Gloss Black.

Here are the pics.

[FLynes]

I decided to go ahead and do the footpegs, since we have an extra hour of light! I also painted the front engine mounts and mocked the bottom end into the frame, to motivate me. I don't think I've been this excited about something, unless you count my CJ-5 restoration, which is a slow work in progress....this resto gives me more immediate satisfaction.

[sstark82]

Really digging the restoration! I was looking for an idea on my engine, debating whether to paint her up or just scrub her down. I like the Duplicolor cast aluminum to the engine idea! looks like that may be the way I go! Here is another idea that you may like. On my 81 atc200 I rebuilt the pullstarter (after the rope broke in my hands) and spruced it up with a few layers of Krylon High Gloss enamel. I am happy with it and it gives a little contrast as well. Let me know what you think!165097

[FLynes]

Really digging the restoration! I was looking for an idea on my engine, debating whether to paint her up or just scrub her down. I like the Duplicolor cast aluminum to the engine idea! looks like that may be the way I go! Here is another idea that you may like. On my 81 atc200 I rebuilt the pullstarter (after the rope broke in my hands) and spruced it up with a few layers of Krylon High Gloss enamel. I am happy with it and it gives a little contrast as well. Let me know what you think!165097

I gotta tell ya that I really do like that contrast and am gonna steal your idea! That looks sharp! I need to completely derust the inside of my starter housing. Since no one makes a decal, I was thinking of making a stencil of the Honda logo, then painting on there.

Thanks for the idea, keep em coming!

[sstark82]

Go to Ebay, There are a bunch of decals and stickers there for these oldies. I believe there was a silver and black one on there the other day, it doesnt say "made in Japan" but it may be a nice addition. There are also original tank and fender decals there as well. Was your seat pan shot on yours? Mine is toast, as you could see, Duct tape and Gorilla Tape is holding mine together.

[jb2wheels]

I love the Duplicolor Cast Coat Aluminum color engine paint. I used it on my 350X swingarm, too:

165098

165099

165100

165101


But I prefer the Duplicolor silver wheel paint for the wheels - it's what I used on these crappy old TRX wheels:

165102

[marc250Red]

Great ! Good job

[FLynes]

Go to Ebay, There are a bunch of decals and stickers there for these oldies. I believe there was a silver and black one on there the other day, it doesnt say "made in Japan" but it may be a nice addition. There are also original tank and fender decals there as well. Was your seat pan shot on yours? Mine is toast, as you could see, Duct tape and Gorilla Tape is holding mine together.

I've seen the tank and fender decals for the 185S....I've also seen the triangular decals that go on the fender, by the rider's legs, somewhere else....I have it all saved on my home computer. Yes, my seat pan was completely shot...rusted beyond repair, but I managed to find a seat on eBay, which has a near-mint seat pan; the seat does need to be recovered, but it only has about three slight rips in it....I got lucky and bought it for $89.

[FLynes]

I love the Duplicolor Cast Coat Aluminum color engine paint. I used it on my 350X swingarm, too:

165098

165099

165100

165101


But I prefer the Duplicolor silver wheel paint for the wheels - it's what I used on these crappy old TRX wheels:

165102

When you sprayed the Duplicolor Silver, did it spatter a bit? One of the things I found, and it only does it with this color, is that when it dries, I have to wipe away the spatter dust...it's weird, but it doesn't affect the final finish.

As you guys get to know me, you'll learn all about my OCD for making sure that things are as near-perfect as possible; I do as much research as possible, before I tackle a problem.....comes from my years in Military Intelligence, only this time my target is a 1982 ATC 185S!

[elevatorman]

Looks Good Fred,I dont think I couldnt bring the motor in the house...lol.Keep us posted

[FLynes]

Looks Good Fred,I dont think I couldnt bring the motor in the house...lol.Keep us posted

I have a very understanding wife. As long as the parts are clean, they're allowed in, LOL!

[sstark82]

I'm still trying to get mine to accept the fact I bought one. Lol

[Dirtweed]

I have a very understanding wife. As long as the parts are clean, they're allowed in, LOL!

My wife is the same. She has been tolerating my John Deere parts for years, now the ATC and Quad parts have taken their place
and it hasn't bothered her at all.

Can't wait to see this one done.

[FLynes]

Didn't get a bunch done tonight; I worked my halter horse for a bit, to get him ready for a show next month, and it was my daughter's birthday....15 years old now. Seems the older I get, the more directions I get pulled in.

I did manage to get the CDI cover, engine mounts and bolts painted. I know the bolts were supposed to be plated, but this is going to be a daily driver, not a museum piece. At some point down the road, I'll probably get stainless bolts for it, but for now I'm happy.

[Direwolf95]

For your restoration are you going to be doing all OEM original parts, or are you going to be doing mods to it as well? i.e. 200x carb, performance piston, etc. And congrats to you and your daughter.

[FLynes]

For your restoration are you going to be doing all OEM original parts, or are you going to be doing mods to it as well? i.e. 200x carb, performance piston, etc. And congrats to you and your daughter.

Direwolf, in all honesty I'm going to slap what will fit on it, so I can get out there and ride. I want it to look as original as possible, but I also understand that some of these parts are hard to find, and I am itching to get out on the trails!

[yoomooman]

i have an 83 185s that i just put a newer lifan 200 elect start/man clutch engine on cause old one was blown but im wondering where to get new rear plastics cause the ones that came separete with mine are way too big, im thinking they are for a 250 but look nothing like yours

where can i get new/used correct plastics or can i modify mine to fit

heres what came with mine and its not fitting at all

http://i73.photobucket.com/albums/i207/pumpman1/DSCN0354_zps7bc78852.jpg
http://i73.photobucket.com/albums/i207/pumpman1/DSCN0355_zps77e9e444.jpg

[FLynes]

i have an 83 185s that i just put a newer lifan 200 elect start/man clutch engine on cause old one was blown but im wondering where to get new rear plastics cause the ones that came separete with mine are way too big, im thinking they are for a 250 but look nothing like yours

where can i get new/used correct plastics or can i modify mine to fit

heres what came with mine and its not fitting at all

Honestly, I don't know. You might want to start your own thread; that will get you more responses. It doesn't really bother me, but posting on someone else's thread is considered hijacking and not cool.

[FLynes]

I got my seat from eBay tonight....holy freakin' cow!!!!!! This thing is mint, considering it's from 1982. There is ZERO rust on the seat pan; the seat itself has four rips....I can deal with that for now, until it needs to be recovered.....a Saddlemen cover will take care of that.

Here are the pics.

[Dave8338]

I think I might cry... :beer

Lovely project that you have going. Any chance that seat came from AZ or Nevada? GREAT parts states. :cool:

[FLynes]

I think I might cry... :beer

Lovely project that you have going. Any chance that seat came from AZ or Nevada? GREAT parts states. :cool:

Would you believe it came from my home state of PA? I remember that, as a kid, everything in PA rusted! God only knows what my 1984 XR100 looks like, if it isn't a Campbell's soup can by now.

[Dave8338]

Would you believe it came from my home state of PA? I remember that, as a kid, everything in PA rusted! God only knows what my 1984 XR100 looks like, if it isn't a Campbell's soup can by now.

Never saw daylight! GREAT find and hard to come by...

[sstark82]

Very nice find! My seatpan looks like your old one. I'm thinking of trying the fiberglass cheap@ss route. Lol. There's a guy on YouTube by the way that recovered his seat on an old ktm dirtbike. Total spent was like $15-20. He takes you step by step and it looks pretty easy. Especially if you have the tools already. Looked like a staple gun, vinyl from wallyworld, scissors and some redneck ingenuity. His finished product didn't look bad at all, and like you said with your ocd you'd probably make it look sweet. :) I just went and got bondo,primer,paint and some sandpaper. Gonna start my tank tomorrow.
Oh and whatever you do, don't line your tank with a liner to prevent rust, the guy before me did that and I am having to peel chunks out with needlenose and carb cleaner.

[Big G]

Coming together nicely Flynes. By the way, glad to see Vancouver Island (B.C.) isn't the only place that gets hammered with rain almost year round!

[FLynes]

Very nice find! My seatpan looks like your old one. I'm thinking of trying the fiberglass cheap@ss route. Lol. There's a guy on YouTube by the way that recovered his seat on an old ktm dirtbike. Total spent was like $15-20. He takes you step by step and it looks pretty easy. Especially if you have the tools already. Looked like a staple gun, vinyl from wallyworld, scissors and some redneck ingenuity. His finished product didn't look bad at all, and like you said with your ocd you'd probably make it look sweet. :) I just went and got bondo,primer,paint and some sandpaper. Gonna start my tank tomorrow.
Oh and whatever you do, don't line your tank with a liner to prevent rust, the guy before me did that and I am having to peel chunks out with needlenose and carb cleaner.

If anything, I'm going to try Evaporust on the inside of the tank....I've had good luck with it. Not sure I'm brave enough to try reupholstering the seat myself, but we'll see, LOL!

[FLynes]

Coming together nicely Flynes. By the way, glad to see Vancouver Island (B.C.) isn't the only place that gets hammered with rain almost year round!

San Angelo is the butt hole of Texas; we get darn-near zero rain!

[sstark82]

Used to live in Odessa, know the feeling.

[FLynes]

What's really sad is that San Angelo used to have 3 nice big lakes with really decent sized bass; now we're down to 1 lake....the other two are literally dry. On a positive side, it makes for good riding trails!

[jb2wheels]

When you sprayed the Duplicolor Silver, did it spatter a bit? One of the things I found, and it only does it with this color, is that when it dries, I have to wipe away the spatter dust...it's weird, but it doesn't affect the final finish.

The wheel paint does - I think it's supposed to give a little texture.
Then engine paint does not. Goes on very smooth. Easy to use.

[Badbmwbrad]

That's a nice way to remember your uncle. Rehabilitating an old object is as much about preserving good memories as it is about restoring the object itself.


...I have a soft spot for things that have been neglected and need to be fixed. Since my uncle, who passed away in 2004, had a 1982 ATC 185S, I thought this would be a great way to feel like he was still around.

[sstark82]

What's really sad is that San Angelo used to have 3 nice big lakes with really decent sized bass; now we're down to 1 lake....the other two are literally dry. On a positive side, it makes for good riding trails!
I know the feeling, used to go to Lake Champion near Colorado City just east of you and now there is just a bunch of weeds,mesquite and dirt. Down here in the swampy southeast side of the state we have water everywhere right now. You should come play in the mud:)

[FLynes]

I know the feeling, used to go to Lake Champion near Colorado City just east of you and now there is just a bunch of weeds,mesquite and dirt. Down here in the swampy southeast side of the state we have water everywhere right now. You should come play in the mud:)

After all the work I've done to make it look new again?????? LOL!!! Well, that IS what pressure washers are for, right?

[sstark82]

After all the work I've done to make it look new again?????? LOL!!! Well, that IS what pressure washers are for, right? that's right! :)

[Direwolf95]

I love this thread, I just got the same trike yesterday and this is a great reference guide to help me restore mine; thank you.
P.S. Keep this thread alive! haha, all the great 185s minds are using this as their think tank.

[sstark82]

Here you go Flynes. I am going to try and post a link to my thread showing some work I did today. http://www.3wheelerworld.com/showthread.php/154693-Before-and-afters-Pics-and-Mods
I probably screwed the link up trying to do it with my phone. :) let me know what you think!

[FLynes]

Nope, you didn't screw it up, link works! I'll be following yours and using ideas for mine too.

I sanded and repainted the recoil cover, but I didn't have enough Duplicolor Black to do the job, so I hit it with the Cast Aluminum....oh well.
I did manage to find a site that has a ton of repro decals for our trikes, ATC Heaven....the guy is in Australia......no one in the US cares enough to do this too?????

[sstark82]

ATC heaven, ok I will check it out. I can find ATC 70 stickers everywhere. Guess we picked the hardest ones to find stickers on.

[sstark82]

I heard a new trick today from a guy who has been working on these little gems for years and he told me to get rid of rust in a tank, all you have to do is drain it, put white Vinegar in it and let it sit overnight. He said the acid in the Vinegar will take the rust out. May have to do it a few times but hey, Vinegar is cheap.

[FLynes]

I decided to finally stop putting off looking at the tank.....what a wreck! The PO left gobs of MIG welds on it, something that looks like some type of sealer that was cracking and lots of rust on the inside. I took the petcock off and it too was a mess, so off to eBay to find another tank. One seller had two tanks, a 1982 185S, which is what I need and a 1983/1984 200S tank. The 185S tank was a bit beat up, but the 200S tank was in immaculate shape, no dings but it is painted white....no biggie, since I'm going to sand it and paint it with the Krylon Fusion Red Pepper, so that everything matches color-wise with the plastic and forks.

Here's a pic of the new tank. I'll take a pic of the old tank later, so you can see how FUBAR it is.

[Big G]

Metal tanks are the only way to go! Good to see you're taking the extra time to re-furbish. Looking forward to seeing how the red color turns out!

[FLynes]

Thanks! My OCD is kicking in just a little, since the tank isn't from a 1982, but I can get over that, given the condition it's in :lol: Once I paint it and put the '82 decals on it, I'll be happy. Most of the metal tanks I've seen are either badly rusted or look like they've been in a rollover.

I've had bad luck with plastic tanks in the past. I don't know if the method of fabrication has improved, but the two plastic tanks I had cracked on me. I'd rather be safe than sorry.

[1982-Honda-185S]

I just read the whole post and What a great job you've done so far man!! Do you have any more pics of the Engine Re-build? And what did you all replace? I'm planning to do everything you've done to yours to mine this Spring/Summer but I'm Debating if i should tear into my Motor and Trans or not. It runs fine as it is, And shifts great. I may re-build the carb though, but Like i said above, Excellent work man!! Cant wait to see the tank all done!!

[FLynes]

I just read the whole post and What a great job you've done so far man!! Do you have any more pics of the Engine Re-build? And what did you all replace? I'm planning to do everything you've done to yours to mine this Spring/Summer but I'm Debating if i should tear into my Motor and Trans or not. It runs fine as it is, And shifts great. I may re-build the carb though, but Like i said above, Excellent work man!! Cant wait to see the tank all done!!

Austin, I have not done the engine rebuild yet, just torn it down to the case, cleaned all the parts and repainted the case. So far, the only thing I've replaced is the seat and the front brake drum. I bought brake handles, because they were missing from mine. Everything else I've cleaned and painted. If your engine works, I would run a compression test on it to make sure that it is within specs, clean it and paint it. Another member here has been kind enough to offer me parts to get me running again, so we can ride.

Thanks for the encouraging words, it really does keep me motivated!

[1982-Honda-185S]

Thanks for the encouraging words, it really does keep me motivated!

:beer And okay, I musta missed it that you didn't actually tear it apart!

[FLynes]

:beer And okay, I musta missed it that you didn't actually tear it apart!

Oh, the engine is torn apart, I just haven't put it back together again with parts in it! :lol:

[sstark82]

Rustoleum Red Engine Enamel worked good for me, if you havent picked your paint yet.

[FLynes]

Rustoleum Red Engine Enamel worked good for me, if you havent picked your paint yet.

I've had incredible luck with Krylon Fusion Red Pepper; it's real close to the red that Honda used in '82.

Went over to Phil Gipson's house today; he and his wife graciously accepted us into their lovely home. Phil and I shot the stuff for a bit and he gave me a bunch of parts to help me with my project, including a 185 engine. All I can say is that it is so great to see people who are this giving; I can only hope to pay it forward as he did some day.

Thanks, Phil!

[philgipson]

the pleasure was all mine.i also found the cd and the holder.pm your address an i will send it thursday when i go into the settlement.

[FLynes]

Got my gas tank this morning.....couldn't wait for UPS to deliver it tomorrow, so I went over there and picked it up. It has ZERO dents on it, but I will sand it and paint it back to the original red color. Then I'll get the 1982 tank decals for it, even though it's from a 1983 200s.

I also put the engine in that phil gipson gave me....I'm still waiting on the eBay vendor to send me the complete gasket kit, but in the meantime I got practice putting it together, tearing it back down and then putting it together again.

Here's a pic of everything mocked up.

[FLynes]

$634.90 later and I have damn-near every single part I need to finish the ATC.

Phil, if it's okay with you, I'd like to come over with Brooke (that way she and Nancy can bond more), and you can supervise me, while I put this beast together again.


I can't wait to fire her up again.....

[philgipson]

sure,just let me know when.i dont know about supervising but i bet two of us with a shop manual can figure it out.the only time i cant do it is the week end of the 12th next month.

[FLynes]

It's Christmas in the Lynes household! I got the first of many pieces needed to finish my trike....the complete gasket kit arrived today, WOOHOO!!!!!

[honda200xguy]

she looks nice!

[FLynes]

A little bit of bummer news.....I stripped the fuel tank today, only to find bondo, Ughhhh! The top has a few dents on top, but at least there's no rust, so I decided to keep the dents for character, at least for now; someday down the road I'll get it fixed properly. I hit it with the Krylon Fusion Red Pepper and it looks great. I also installed the new rope and grip for the starter, the spring that holds the seat latch in place, the NOS hand grips and painted the metal end caps, the NOS rubber grommets that hold the headlight frames in place and installed the wiring harness, which is in immaculate condition, compared to the old one. Last thing installed was the new sprockets and chain, along with the aluminum chain guard, which was missing.

Here's a pic.

[FLynes]

Quick question for you gurus....what size are the exhaust studs? One of mine was bent, so I need to get new ones.

[FLynes]

Anyone, anyone? Bueller, Bueller?

Great movie.

[Dave8338]

I'm thinking they're 6mm x 35mm. Not sure on the thread pitch, however. OH... they are a ferrous :naughty: metal. :lol:

[FLynes]

I'm thinking they're 6mm x 35mm. Not sure on the thread pitch, however. OH... they are a ferrous :naughty: metal. :lol:

Thanks, Dave! Yes, quite ferrous!:lol:

[FLynes]

A couple more things came last night, the coil, the CDI, rear handbrake cable and the headlight.

[Dave8338]

Look'N GOOD! Keep up the effort, it is fun to see another 185 being brought back to life.

[FLynes]

Look'N GOOD! Keep up the effort, it is fun to see another 185 being brought back to life.

Thanks, Dave! I have to say that this has been a lot of fun, but it'll be a lot more fun to fire her up for the first time and ride her, while my uncle is looking down from above.

[FLynes]

WOO HOO!!! Front fender and tail light came in yesterday.

Slight problem, though......anybody know what size those bolts are to hold the fender in place? I'm missing the top and bottom ones.

[FLynes]

Last night my Duro HF240 tires arrived from BikeBandit.com .....now I can get rid of those ugly knobby POS tires that are on there!

[bumsted200s]

Quick question for you gurus....what size are the exhaust studs? One of mine was bent, so I need to get new ones.

Typically 6mm is a 1.0 thread pitch because the diameter is so small. Most tap/die sets have a thread gauge in them. 35mm length sounds about right.

Just read through your thread, looks good so far. I have a '82 185S myself all restored, nice to see someone else doing the same. Very common machine (atleast by me) but most people tend to not fix them up. Regardless what you use it for... they make great trail riding machines especially for the size & weight you can't beat it. Added a PRM 6 pack rack to mine and in combination of 50 mpg +/- and a 2 gallon can it'll take you a long ways. Like to see them piece of junk 4X4 mini sherman tank auto brake clutch belt chewing 4 wheelers do that.

Fyi- There's much more upgrades that I didn't read about or might not be aware of. For example 185S/200S have same everything minus cylinder, so putting a bored 200 jug and piston is easy did that to mine. My 200S/200X both run high compression Web Camshafts (fits 185S) megacycle makes the same but in a needle bearing conversion, heavy duty vavlve spring kits are available. PBI sprockets makes smaller or larger sprockets if you want increased speed. The rear axle hubs will accept 200X or 400EX hubs so you can run 4/110mm bolt pattern for limitless rim choice.

Good luck with finishing it. Also noted glad to see you're cutting those ugly carlisle knobbys off. Even if you have new tires bought, I run 20" rears on mine versus the stock 22". Didn't notice speed difference but the acceleration is much quicker.




my wheelers
'81 200 (5 wheeler)
'82 200 Hondapotomous
'82 250R
'82 185S
'84 200S
'85 200S
'85 200X

[FLynes]

Typically 6mm is a 1.0 thread pitch because the diameter is so small. Most tap/die sets have a thread gauge in them. 35mm length sounds about right.

Just read through your thread, looks good so far. I have a '82 185S myself all restored, nice to see someone else doing the same. Very common machine (atleast by me) but most people tend to not fix them up. Regardless what you use it for... they make great trail riding machines especially for the size & weight you can't beat it. Added a PRM 6 pack rack to mine and in combination of 50 mpg +/- and a 2 gallon can it'll take you a long ways. Like to see them piece of junk 4X4 mini sherman tank auto brake clutch belt chewing 4 wheelers do that.

Fyi- There's much more upgrades that I didn't read about or might not be aware of. For example 185S/200S have same everything minus cylinder, so putting a bored 200 jug and piston is easy did that to mine. My 200S/200X both run high compression Web Camshafts (fits 185S) megacycle makes the same but in a needle bearing conversion, heavy duty vavlve spring kits are available. PBI sprockets makes smaller or larger sprockets if you want increased speed. The rear axle hubs will accept 200X or 400EX hubs so you can run 4/110mm bolt pattern for limitless rim choice.

Good luck with finishing it. Also noted glad to see you're cutting those ugly carlisle knobbys off. Even if you have new tires bought, I run 20" rears on mine versus the stock 22". Didn't notice speed difference but the acceleration is much quicker.




my wheelers
'81 200 (5 wheeler)
'82 200 Hondapotomous
'82 250R
'82 185S
'84 200S
'85 200S
'85 200X

Thanks for all that great info. I didn't think that the 185S was all that upgradeable, but you learn something new everyday!

I got the mud flaps in tonight, as well as the tank decals and the fuel cap.

Here's my old tank vs the new and mounted on the trike. Sorry for the pic quality....iPhones just don't have a great flash.

[FLynes]

I didn't get a bunch done today. I rebuilt the Keihin carb and then spent the better part of an hour cutting the front tire off of the wheel.....couldn't break the doggone bead, so I sliced it up with my boxcutter. I then took a wire flap wheel and put it on the HF grinder and went to town getting all the crud off of the inside of the wheel. Cleaned and painted it.

Tomorrow I'll go over to TSC and get some valve stems and then get to work on reassembly, then I'll tackle the rear wheels.

[FLynes]

Couldn't sleep last night, so I decided that it was time for a marathon session; I stayed up until 4AM and finished everything I needed to. I degreased and painted the engine that Phil Gipson was gracious enough to give me, put new gaskets in the top end, reassembled everything and set the valves to .002 inches per the manual.

I did run into a problem though and need some help. When I was assembling the driven sprocket, I noticed that the damper holders weren't mating up to the sprocket the way they are supposed to; the sprocket isn't sitting perfectly centered the way it's supposed to be. The result is that, when I assemble the chain, I have a moment where the chain is a bit slack, followed by a moment where the chain is hyper tight. I've checked runout on the axle and it's fine, so I know that's not the problem, so that leaves me with the sprocket itself.

The question is how do I get the sprocket to sit as it should so I get equal tension on the chain?

[FLynes]

Major f'ing setback.....got everything installed, added gas and tried to start it.......nada. I pulled the plug wire and saw no spark......faulty CDI unit? faulty pulser generator? faulty AC generator? Who knows? I go inside to sort it out and go back to the garage five minutes later............to find gas leaking all over the place from the tank........F@%#!!!!!!!!!!!!!!!!!!!!!!

Back to square one.

[FLynes]

Well I regrouped and, with the wife's blessing, found another tank. The biggest demoralizer was all of the time and effort that I spent on the first tank. It goes to show that, even if the eBay seller has a 100% feedback rating, they can still be less than stand-up.....I messaged the guy and told him my issues and he never responded. Cross my fingers that this one has no leaks.

The next issue is the no start. I'm finding out that the made in China parts aren't up to par with the OE specs. I wonder if that has something to with it? Is there a site that still sells OE parts?

[8L4ckVVid0]

that 185 is looking great! I can't wait to start on a project of my own. Good luck with the rest of the build!

[FLynes]

Well, here is the superficial final product. I'm still waiting on the replacement 200S tank, axle and decals from ATC Heaven.

The new tires make it look a million times better. I can't wait to fire her up and go down the road.

[sstark82]

Wow Flynes!! I haven't been on in a while to check your progress but she looks Awesome!! Very well done my friend!

[FLynes]

Thanks! It looks radically different than when I first got it. I can't wait to ride it.

[steck]

definitely need a before and after pic side by side...

[Dave8338]

FANTASTIC ! ! ! ! WOW... does that bring back memories. GREAT job on the restoration. Which tires did you go with, they look OEM in the pic?

[FLynes]

FANTASTIC ! ! ! ! WOW... does that bring back memories. GREAT job on the restoration. Which tires did you go with, they look OEM in the pic?

I went with the Duro HF240 tires, as they are the closest thing I've found to the OE Ohtsu's.

Here's a before and after.

[Worden18]

Looks awesome! Have fun with it :)

[elevatorman]

Looks great. you can do mine next...lol.

[FLynes]

Looks great. you can do mine next...lol.

LOL, no way! While I had a blast doing this, I will say that it took a lot out of me and I won't be doing this again for quite some time. I did decide to sell my '76 CJ-5, so that the whole family can have fun together, however the wife wants quads for her and the kids.

[Dave8338]

I went with the Duro HF240 tires, as they are the closest thing I've found to the OE Ohtsu's.

Here's a before and after.

You should be proud. Ya just saved a piece of history and in the process, kept 1 more 185 out of the scrap pile. GREAT job !

[FLynes]

Thanks, Dave. Like I said before, since I am incapable of being physically fixed, it gives me satisfaction to bring something that is neglected back to like-new condition.

[ncorry]

What happened with the first replacement tank that caused it to leak? Have you tracked down the no spark issue yet? Great thread, and thank you for your service.

[FLynes]

What happened with the first replacement tank that caused it to leak? Have you tracked down the no spark issue yet? Great thread, and thank you for your service.

From what I can tell, according to the crinkled Krylon paint (KRYLON DOES NOT REACT WELL WITH GAS!!!), the seam is cracked. Since the top is dented, getting a new replacement was in order. I haven't tracked down the no spark issue yet, however I did do a compression test and only came up with about 75psi....no es bueno. The top end is going to have to be redone.

[FLynes]

I did get my little buddy to hop on for a photo op.

[FLynes]

Here are some pics of the decals I got from ATC Heaven. I still have to smooth out the bubbles on the left side decal.

[FLynes]

Well folks, I learned a valuable lesson in rebuilding this trike.......never order parts that are Made in China. I tested the resistance on the replacement chinese coil and got nada on the wire side; the primary side had .8 ohms, within specs.

I went to Babbit's and ordered an OE coil, wire and suppressor, as well as a headlight bulb and a ring set. As soon as the parts get in, I'll take the trike over to you, Phil, so we can get this beast fired up.

[FLynes]

My replacement '84 200S tank came in tonight....the pictures on eBay did not do it justice.....ZERO RUST inside and NO LEAKS! I've never seen metal look that good in a tank. The clearcoat is faded, however I don't care, because it's just going to get sanded, repainted and a new set of '82 decals; this time it gets shot with Duplicolor (Krylon and gas do not work well together!).

Now all I need is the OE coil, piston rings and replacement axle, then hopefully she fires up!

[FLynes]

The replacement OE axle and sprocket assembly came in this evening. I will never ever buy anything made in China again. The OEM coil and piston rings should be in Friday. :w00t:

[Larry T Moore]

Im on the edge of my seat with this one...outstanding!

[FLynes]

Well folks, she's done. The stator was the culprit, and I managed to get a NOS for a 1981 off of eBay. I recrimped the black wire to fit my harness, crossed my fingers and pulled the rope. First try and she fired right up!

Here's the vid: http://youtu.be/PG0ACZkMUnY

I rode for four hours today; my Uncle John was smiling from above the whole time.

[FLynes]

There's an old Victorian house down the road that's been abandoned for decades. It was built in 1903 in another town and then moved to its present location in 1965. When I was riding by it this morning, there was a crew there tearing it down. I stopped to talk to them for a few minutes, and the first thing that one of the guys said to me was, "I thought those were illegal". I had to chuckle to myself, then I told him that no they weren't and his response was, "Well they're kid killers". "Only if you believe 60 Minutes friend".

Amazing.

[elevatorman]

Thats awesome Fred, I know your uncle would be proud.