My ATC 200E repair thread. Now running and rolling!!!!!

[Yamada]

So, today I dismounted the engine of my Big red because the head gasket was leaking. Everything seems to be in good condition. No abnormal carbon build up on the piston, the head and the valve. This week I'm gonna order a gasket kit at the local Honda dealer. So, my question is how should I prep the cylinder and head before assembly? One of my friend is machinist and he told me that he could shave my head ( so I know it will be strait and clean:naughty: ). As the gasket was blown, there is carbon residus on the cylinder. Can I use some kind of brake cleaner, or razor blade??? Please tell me what do do.
Also, this is my first time at "rebuilding" an engine, so fell free to add your trick and comments.
Sam

[Liquid-Darkness]

I wouldn't shave the head if I were you. That will bring the valves closer to the piston. At the most, take a Mill B@asard file to the bottom and rub it a few times. Pop your valve springs off and lap those valves. Install some new valve seals and throw the springs back on. You could take a small screw driver and pick off some of the carbon deposits. That will give you a like new head that should be good for a few more years. Some people check the valves with a micrometer for wear and they check the springs with a caliper. Replace if needed and thats about it for the head.

[Yamada]

Thank you for your help Liquid but I don't think I'm gonna remove the valve, because I don't have the tool and because I plan to change the engine :naughty: I just want it to be running this winter for some snow riding.
How do you clean the surface before assembly?

[Liquid-Darkness]

The surface of which side?

[Yamada]

Where the head gasket sit on.

[Erics350x]

soft wire wheel and a drill.

[jason 32]

have the machinist do it -it wont be shaved just milled to a flat surface-
if its warped it needs it- or it will keep blowing gaskets
assemble- torq it, and use red locktight

[Yamada]

Thank you for the info guys. I take note. So I will tell my friend just to lightly mill the head to be sure it's strait.
Today I went to my local Honda stealership and ordered some part. For 170$CAN, I have a complete engine gasket set, carburetor rebuilt kit, front and rear sprocket. At that price I still don't have the chain. The sprocket were so worn that the chain was skipping on the front sprocket when I shifted the second gear.

[jason 32]

dennis kirk man- you can get a ton o stuff from there- 1-320-358-1916

[Yamada]

dennis kirk man- you can get a ton o stuff from there- 1-320-358-1916

yeah, if only I live into the USA. I don't want to buy part at a 10% discount and have to pay for the shipment and maybe the custom fee. Plus, the guy at the dealer tell me my parts should be in thursday.:beer
Ok, I made some research and at Dennis kirk, the price for the front sprocket is $54.65. At the Honda dealer I pay 41.95 $CAN:D

Dennis kirk's Rear sprocket: from $33 to $50.95 and I pay 36.95$CAN:D

Dennis kirk's Vesrah complete gasket kit: $38.99
Honda dealer unknown brand gasket kit: 46.95$CAN:cry:
So finally the price i got are not so bad.

[Yamada]

I just received my head and cylinder from my friend. The surface just needed a cleaning. He told me the head was not warped. So far I replace the rear sprocket and I'm stilling waiting for the front sprocket to arrive. This afternoon I plan to buy a torque wrench and start to assembly the top end tonight.
After the engine re-assembly I plan to put it back into the frame and change the drive sprocket. On these ATC, you have to remove alternator and the sub-transmission to reach the sprocket. I will try to post a pics of the old front sprocket, I'm certain you never saw a sprocket that used. I think the previous owner never replaced the sprokets and chain. With the chain flat on the ground, I'm able to form a "U" with the chain.

[Big red 200es]

C`est plate en crime quand que ça coule l'huile par la tête mon 200es IL faisait ça avant que je refaisse la tête. J`espère que ça coulera plus en tout cas le mien juste des gasket neuf puis ça a arrêter de couler.

Ps-Aujourd'hui j'ai installer mon essieux neuf (acheté usagé pour 60$)

J'était content de refaire une ride de 3 roues ça faisait longtemps.

Tu mettra des photos de ton Big red

NIck

[chris200x]

C`est plate en crime quand que ça coule l'huile par la tête mon 200es IL faisait ça avant que je refaisse la tête. J`espère que ça coulera plus en tout cas le mien juste des gasket neuf puis ça a arrêter de couler.

Ps-Aujourd'hui j'ai installer mon essieux neuf (acheté usagé pour 60$)

J'était content de refaire une ride de 3 roues ça faisait longtemps.

Tu mettra des photos de ton Big red

NIck

Canadians... :rolleyes: :wondering

Those prices on the sprockets seem terribly high to me for some reason? I can get a aftermarket front sprocket for 12 bucks. Or did I misunderstand it and that's including customs and international shipping?

Anyway good luck on your bulid and keep us updated. :pics:

[Yamada]

Canadians... :rolleyes: :wondering

Those prices on the sprockets seem terribly high to me for some reason? I can get a aftermarket front sprocket for 12 bucks. Or did I misunderstand it and that's including customs and international shipping?

Anyway good luck on your bulid and keep us updated. :pics:

Your 12 bucks front sprocket must be for a Honda 200 without the subtransmission. The way I see it, the 200e sprocket is different from all the others honda 200. And the price from dennis kirk doesn't include shipping and custom fees.

Also the cylinder and cylinder head schematic show 3 dowel pins to hold the head gasket, the problem is that when I dismounted the head, there was only two of them. It's seems strange to me to put 3 dowel pins because there one of the hole in the head that is not tapered (???) to sit the dowel pin and seal it. I think I will play it safe and I will wait and buy this dowel pins.:(

[scary132]

I realize I'm a little late... but I got my 200e front sprocket and some other stuff from Hyperparts.

http://hyperparts.com/wc.dll?ctwp~iteminquiry~1001~1002~H833426

Best deal I found.

[chris200x]

huh? I didn't realize the front sprockets were diffrent like that. I was thinking just a plain old ordinary sprocket.

I learn something new everyday.

[edog]

You really cant see the long part of it.It is in the case.


I was suprised as well when I looked at mine.

[Yamada]

I realize I'm a little late... but I got my 200e front sprocket and some other stuff from Hyperparts.

http://hyperparts.com/wc.dll?ctwp~iteminquiry~1001~1002~H833426

Best deal I found.

Yeah they look to have some great deal. I bookmarked the website.
I hate this, because of the missing dowel pins I can't continue the rebuild.
Anyone got a 10 x 20 mm dowel pin laying around??? If not, I will have to order it at the dealer, I'm sure they don't stock this $1,12 dowel pins

[McDerry]

Awesome Parts Source.

Had been looking at getting new sprockets for my TRX125 (Rear is worn, front is worn and chipped on a couple teeth), in addition to the gasket set. Hadn't seen any vendors listing it all (some had the front sprocket, some the complete gasket kit, etc.) Ran me $112 plus shipping charges (est $12) For front and rear sprocket, chain and the complete gasket kit (just refreshed the valves and to switch the front sprocket) from Hyper Parts. MFG supply was listing the front and rear sprocket and chain for $90 alone. Would still have to hit up DennisKirk(or equivalent) for the complete gasket kit for another $35-$40 plus shipping, but mind you they didn't offer a front sprocket.

As for the dowel pin, I'd hit up Beatrice Cycle/DRATV. He has a ton of those smaller engine parts people loose and his shipping is descent (USPS).

[Yamada]

Today I received a 200x cam :naughty:. Still waiting for the back-ordered front sprocket to arrive:mad:
Anyone know if the 200x valves springs are stonger on the 200x head? I don't want the valve to float when I wide open on the trail.

[RedRider_AK]

You can probably stick stiffer XR200 springs into it. If not, I am willing to bet the 200X springs are stiffer, due to the bike's purpose.

[Yamada]

So I checked if the 200x use different valves springs and Bikebandit list the same parts numbers for all the valves springs between a 82 200e and a 83 200x. So I will be ok.

[Yamada]

Quick question. On the rear right dowel pin between the cylinder and the head there is an o-ring around it. When I dismounted the engine there was a green o-ring, but it was cut. Was it the right o-ring? Is it a black o-ring that goes there?

[Howdy]

Quick question. On the rear right dowel pin between the cylinder and the head there is an o-ring around it. When I dismounted the engine there was a green o-ring, but it was cut. Was it the right o-ring? Is it a black o-ring that goes there?

The green o-ring is the proper one for that dowel pin. The reason for that o-ring is to seal that dowel so that the oil will get to the head / cam, ect. The oil comes up along that stud to the head / cam.
Howdy

[McDerry]

As howdy said its a pressurized journal for the overhead cam. You want a o-ring around it prefferably uncut.

[Yamada]

Thank you Howdy and McDerry. I knew the cut o-ring was not a good thing because when it was running oil was dripping around the head gasket.

[Yamada]

Today I went to a motorcycle salvage yard and found the dowel pin that was missing. What was funny is that the guy just went behind his working table, pulled a head that was on a pile of part, removed the dowel pin and gave it to me. He said, my wife don't want i sell these part, she just want me to gave them. Just give me $1 and it'll be ok.
At least now I know where to get parts for my trikes, he had at least 5 atc-200 ( don't the model, just no x), maybe 2 250sx, 1 atc-110, 1 atc-125 ( with the horizontal engine), 1 yt-125, maybe 2 ytm-200 or a ytm-225. They looked to be complete except for some missing pull start and flat tires.

Tonight I will rebuilt the engine and if everything goes well, put it back into the frame and try to start it.

[Yamada]

Well, I just finished to put the engine back together. I did a compression test and the result is 135 psi. I think it is pretty good. Maybe tomorrow i'll havethe time to put the engine into the frame and fire it for the first in 4 months :woot:
I small problem I encountered is that I use a 200x cam in the 200e head. The manual call 0.08 mm of valve clearance for the 200x and 0.05 mm for all the other models. I set the valve to 0.08 mm, do you think it is correct?

[Yamada]

I just fire it!!! It fired after 5-6 pull of the cord. I only had a fouled plug so I think with a new plug the engine will run like a champ. Now all I need to do to ride it is change the drive sprocket and put a chain. I can't wait to take a ride!

[bigreddaddy]

:pics: :pics: :pics:

[Yamada]

:pics: :pics: :pics:

Nothing special with this trike but once I receive my sprocket and chain I will try to take some action pictures:naughty: .

[Yamada]

Yesterday I finished to replace the front sprocket. Let me tell you that it's not a 10 minutes job. You have to remove
the recoil starter,
the subtransmission,
the starter and starter gear,
the electrical stator ( I'm lucky to have a air impact in the garage, if not I would still be !*!$6++^%*@ at the Big red, )
the case spacer
to reach the sprocket.
The new sprocket just take 10 sec to slide on the shaft but you're not halfway of the job. You have to clean all the gasket mating surface of the different parts of the engine cases. One bottle of gasket remover later I was ready to reassemble the engine.
It took my 25 min just to mesh the chain on the front sprocket, someone that worked on a 200e will know how it's a tight fit.

I still have some fine tuning on the engine to the but it's now moving on it own power :beer
This week I will try to post pics of the trike.
Can't wait to see now how it will compare to the ytm-200.