200s rebuild

[Ironheadtmb]

Hi all Iam gonna start to order the parts I need to rebuild the top end of my 200s and was wondering is there one kit I can buy or do I have to try and find all the parts that's needed individual? Gonna rebuild head new piston ect thanks for your help

[ironchop]

Before you buy anything, measure the stock bore in several places and see if it needs just a hone or an actual bore job. When I figure that out, I'll buy the appropriate piston and then I set up my cylinder and bore it to the piston size taking in account necessary clearances.

I got lucky lately and got a 200E that only needed a hone and new rings. Cleaned the carbon off the top and the skirts looked great. Rings were still good too but I replaced them anyway. Honed the bore and changed rings and it's ready to install once I need it.

On your other question, there isn't a complete top end "kit" on that motor. You can get a gasket set but outside of that, as far as I know, you'll need to source the pieces separate. The good news for that is that the 200S,M,E,ES,X,XR models all share most everything but camshaft and some have decompression levers in the valve cover. 185S I think also shares some stuff topend wise.....so it shouldn't be hard to find everything you will need.

I would strongly suggest to change the timing chain guide and tensioner when you change the timing chain. I've run into a few of these 200 motors lately with worn out timing components allowing the chain to jump the sprocket and bend valves.

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[Ironheadtmb]

Thanks ironchop planned on having it honed your right that will determine the piston size thank you

[Bren_downe]

G and H discount atv offers full kits and machining. I've never used them but I've heard good things.

http://www.ghdiscountatvsupply.com

[ironchop]

G and H discount atv offers full kits and machining. I've never used them but I've heard good things.

http://www.ghdiscountatvsupply.com
Thanks for that link. I learn something new every day!

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[yaegerb]

You could also send it out to John tice for a hone or bore. He is in your neck of the woods.

[Ironheadtmb]

I'll look him up yaegerb thanks and thanks for the link bren. While its apart should I do valves too cam?

[yaegerb]

I would at least do valve seals and you could cam it but not necessary.

[Ironheadtmb]

Thanks atc King that's not a bad deal

[ironchop]

G&H also sells their rebuild kits on EBay. http://www.ebay.com/itm/84-86-Honda-Atc-200S-Engine-Motor-Complete-Top-End-Rebuild-Kit-Machining-Service-/350690585919?hash=item51a6c9ad3f:m:mDBUcdDFOaujfok zrj0nPoA&vxp=mtr

Presuming the valve guides and seats are in good condition, that'd be a one-stop shop. They even include a new cam chain and cam sprocket.

The only extra cost is shipping the cylinder, but Flat Rate USPS shipping isn't much and the cylinder will fit in one of the smaller boxes. I've shipped quite a few engine parts that way, just pack the cylinder well so no fins get broken. Make sure to remove any dowels too.

The bottom ends on those engines should last through at least a couple top end rebuilds, unless the small end of the rod is damaged. There is a bushing on one end of the camshaft - http://www.bikebandit.com/oem-parts/1984-honda-atc200s/o/m1894#sch11198 - it's not in the G&H rebuild kit, but you still need to at least inspect it and replace if necessary. Unless the camshaft has damage, they seldom need replaced, and typically the damage is the result of extremely dirty or low engine oil.
I was thinking the other day while trying to sort out my sister's 200E and 200ES that I wished I had asked for your number at TF15.

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