Time to Get Started on My ATC200M

[Social Torture]

I'm planning to get started on making one decent machine out of two. Surgery will begin, at dawn.

I'll be playing with a $100 1983 Big Red and a $40 1984 ATC200M. The 200M has the best frame and fork, the tires don't appear to have much use on them, and the tires seem to hold air. I'll have to check the air pressure, after the sun rises. I'll be trying to 200M. The 83 Big Red will be offered as a sacrifice, so that I can use its parts. Hopefully, it will turn out give off a sweet aroma of exhaust fumes when it's all said and done.

If the 200M runs, I'm planning to do the following.

- The gas tank on the 200M does not look too good, but I have a plastic tank on the Big Red, so that's okay.

- The gas tank did have some sludge in it, and the petcock was left open for an unknown number of years. I hope I'll be able to get the carb cleaned up. If not, I'll be peeling the one off the Big Red.

- The 200M needs both drive sprockets and a drive chain. I'll just use the rear sprocket and chain from my Big Red. I'll have to buy a front sprocket. I'll check with the local graveyards.

- The guy that sold the 200M to me that it needed rear axle bearings. At least I can get those for cheap.

- The key switch is gone, but thanks to sages of this forum, I have the information to bypass the keyswitch. You people are great!

- The 200M's rip cord does not grab, so I won't let a certain sacrifice go to waste.

- Install a taser, with a 10 second time delay, into the seat. Stealing my machine might prove to be the shock of a lifetime. Okay, I won't be doing that, yet... mainly because I don't like courtrooms.

[Big G]

Good work Doc! Throw in the odd pic as things progress :p

[redsox]

i restored an M about two years ago. i like them, but they're not terribly popular. its the model nobody loves! you can get parts, and people on here are a ton of help. i swapped out the front forks from a big red. I like the headlight and front rack much better than the M, and it was a simple swap. good luck. post pics!!

[Social Torture]

This is where I am, now.
-The engine on the 200M is seized. The carb was terrible, and I had to disconnect the trottle cable at the handlebars, just so I could remove it. I don't think the carb is salvagable. $40 was a great deal for a rolling chassis, except the rear end bearings and the seized rear brake. That isn't so bad. The 200E has a solid rear end, with a functional brake, and the rear sprocket is already mounted, so I won't complain. I did manage to yank the rear end out the 200M, and I loosened the rear end bolts on the 200E.

I know that the 83 200E and the 84 200M were almost identical.

This is what I'm planning to do. If any of the sages out there have reason to believe that anything might not work, show me the way to knowledge that leads to the bliss of the wind whipping against me when I'm going fast.

This is what I'm planning to do, next.

The engine on the 83 200E runs. Will Big Red's engine bolt on to the 200M, or will be Big Red's sacrifice be all for naught?

The rear end on the 200M isn't in the greatest condition. The bearings are shot and the treaded mounting hole (top left) doesn't have any threads left, but has clean rims with decent tires that actually hold air. Hooray, for usable tires! I am planning to install Big Red's rear end.


Good work Doc! Throw in the odd pic as things progress
Who knows, maybe I'll go from being a doc to an appretice miracle worker. Okay, I guess I shouldn't get too far ahead of myself. LOL!


i restored an M about two years ago. i like them, but they're not terribly popular. its the model nobody loves! you can get parts
Nobody loves it... Dang it, anyway. There's all these parts... and nobody wants them. I guess I'm just going to have to step up and take all this stuff home with me. That sounds about like the same attitude that I have with my Mosin Nagant... since it's about the only thing you can get ammo for. LOL! I'm not going for restoration grade material. I'm just looking to make a solid unit that I'm not afaid to ride.


and people on here are a ton of help.
You got that right!


i swapped out the front forks from a big red. I like the headlight and front rack much better than the M, and it was a simple swap.
I agree with you on Big Red's headlight assembly and rack, but that's not an option... at least not yet.


good luck. post pics!!
I'll need it, since I am taking on, not one, but two Honda ATC's. Everyone knows that those things were notorious for murdering innocent people. Perhaps, they masters of some, unknown form of judo. When I brought them home, the truck didn't even flip over. I was surprised, to say the least. LOL! I'll be sure to post pics.

[Big G]

Well not bad progress for first day under the scalpel!

[Gearheadtom]

Yes, the motors will swap. I ran a 200m with a 200e motor in it for years.

[Social Torture]

Yes, the motors will swap
Thank-you for that information. I'll finish swapping those rear endd get right to swapping the engines.

How do I go about swapping the CDI units? The advance isn't working quite right on the 200E. I removed the CDI cover to look at it, and the part that advances the spark is not springing back. The 200M is spring back, just fine.

If it isn't raining, I'll get back at it in the morning. I ralready removed the fenders, foot pegs, and gear shift levers. All I need to do is remove the hanger bolts, swap the engines, and tighten them back down. I have pulled the engine and reinstalled it, not too long ago, so this shouldn't be too bad of a job as long as I don't have to fight with any stuck bolts. I'll try to get some pictures of it before I go at it again.

[Gearheadtom]

To swap the advancer unit, you've gotta take the cover off, take out the 10mm bolt in the center holding it to the cam. Then I believe to get it out you have to take out the two screws holding the CDI pick-up ring. Mark where it's located, as that controls your spark timing. Then you should be able to slip the advancer unit from one motor to the other. Try not to remove the rotor from the advancer assembly, because there's two ways to put it in, and it won't run if it's in backwards.
Hope that makes sense.

[Social Torture]

I have some video footage that I'll have to post when I'm using a better internet connection. Hopefully, I'll get it posted this Sunday.

Anyway, here's where I'm at. Big Red's engine and rear end was tranplanted to the 200M with success. I got Big Red's drive chain on the 200M, as well, but it seems like it's way too tight. I had to fight really hard to get the master link back in it, with the rear end moved as far ahead as it would go. I took it for a very, short spin around the yard, and it doesn't seem like it's pulling to one side, so that's cool. A good fork, that isn't bent and completely worn out, is really nice! Since the key switch was not there I followed the instruction from another thread, so that I could get those wires contained.

Here's the next set of things, for me, to do. There's a few question in here, too.

- I can hear a squeak coming from the rear end, and it's not the brakes. I think my chain is too tight, even with the rear end all the way forward. I'm going to have to add at least another link to my chain. What is the chain size for an 83 Big Red? What about the chain size for an 84 200M? This might sound a little crazy, but what size of chain was used on the ATC110. The guy I bought the 200M from also has a 110 that he'll part with for $20. I do not know the year of the 110. He told me that it needed rings and a rip cord starter. The engine wasn't siezed when I looked at it. Since it's not siezed, it can be fixed. I don't have a lot of use for 110, but $20 is really tempting. I just don't want to see some child get ahold of one of those death traps. LOL!

- The air box was an improvised, mass ladybug grave, so I'm sure the light switches are pretty grimey. I'll be taking those apart and cleaning them.

Two of tires on the 200M hold air, and I'll be putting them on the rear, since they're the same tires. I be pulling one off the Big Red to get a complete set of tires that actually hold air.

- Since I'll be putting a different tire on the front of the 200M I might as well pack it with grease. Would it be a good idea to put a grease fitting on the front hub? Would putting a grease fitting on the rear end be a good idea? If not, why?

- I want to eliminate the Neutral light. Can it be done without messing something else up.

- I'll be making my own rack and rear fenders. For the rack, I have a piece of aluminum expanded metal (it sort of looks like catwalk materal) that's just the right size, for a functional rear rack. I'll fabricate some sort of fenders, that I'm planning to hang from the rear rack. I'm not worried about getting dirty. I don't wear new clothes while I'm riding, anyway .I just want something to prevent me from getting sucked underneath the rear wheels.

- I'll have to get a rear foot brake cable because the one off the Big Red was a little too short for the 200M. At least Big Red's rear handbrake cable was long enough.

So far, this has been a lot of fun. It has been quite educational, too.

[diesel]

If you get the 110, I need some parts from it, if you want to part with them. depending on the year. PM Me.

[Gearheadtom]

I believe the 110 uses #428 chain, and the 200e/m uses #520 chain. From what I remember the 200e has two less links then the 200m, but since the chain is probably old and stretched, it partially makes up for being two links short for the 200m, so you can get it on, but it's still to tight.

[Social Torture]

The 84 200M has offically been resurrected, thanks to the honorable sacrifice of the 83 Big Red. "Big Red, your sacrifice will never be forgotten." LOL!

It runs, the lights work, and the electric starter even works. It's... so... so... inredibly... beautiful! [Social Torture begins to sob]

All I have left to do is put the taillight on and swap the CDI unit, and I'll be able to cheat death, once again.

After I complete it... I might not make it back that day. Seriously, I might end up going for a week long ride. LOL!

[Social Torture]

I was successful at swapping the CDI unit.

The lights have been hooked up, and they do work.

I ordered a chain, and it should be here on Wednesday. I should be able to go fasting by Independence Day.

- I think my charging system might be shot. My battery is being discharged when I have the lights on, but it does not appear to be charging. What should I look at, and how do check/test it?