did i do this right ? High Res Pics Inside

[ThinktwiceZ71]

hey guys , i had to tear apart my 85 200s motor cause the inner crankcase cracked and leaked , so i got both sides tig welded . My concern is this , i am nervous i am gonna mess up something with the transmission gears when putting back together. I Found a free copy of the honda service manual online for my model ( the shop one 211pages)

I just want to make sure i put the shift drum back in right , and that the forks are in the right spot and that they are in the drum in the right places. If i grab the mainshaft i can spin it freely , and if i grab the shift drum i can rotate it a little and i can feel something click (like when i shift when i am riding ) that noise.

So....does this look right to you ? all the thrust washers and gears are in the right order , i have checked like 10 times , washers are in right spot also .

I just don't want to have to take this whole engine apart again after putting it back together to find out i F'ed something up .

Thanks Guys .....Nervous in NY

ps....i am mechanically inclined , i replaced a water pump in a pontiac 2.4l engine , had to rip half the engine apart , and that turned out fine first try. Just this is the first time i have ever messed with a ATV , Small engine before.:confused:

[ThinktwiceZ71]

anyone ? i just want to make sure the shift forks are in the right slotts on the shift drum

[seadoo650]

Looks good t me. I think they can only really go in one way. Try running it around by hand a shifting through the gears.

[Mosh]

If you did the BS timing chain and waterpump in the dreaded quad 4 GM engine, I think you will be fine here.

Most of the time, the trans and forks will only go in 1 way.
When in doubt, I loosely bolt the cases back together and run the thing thru the gears and make sure they all engage..Then apply the gasket and bolt together for good.

Take a extra hour and go over it again, and it will save you time later!

[Dirtcrasher]

They usually have "R" "L" "C" stamped on them and that faces up (depending on which case you place them in!)

Then you only have the 3 grooves.....

I'd just be careful if you had every gear off the shaft, gears can be installed 2 ways and only one way allows the "shift lugs" to fully engage. You can usually tell by the wear pattern which way faces the lugs.

I usually do a "dry run" anyhow. I have bolts I cut that head off that either fit the main or counter shaft and then I spin it with a cordless drill and shift through the gears.

You've got a manual so your about 10 steps ahead of most people!! :D

What was the reason for splitting the case anyhow??

[ThinktwiceZ71]

the case had 2 small hairline cracks in it , i tried jb welding to no avail , so i cleaned it all up , had a professional tig weld it , but it was soooo close to the gasket it cooked it. So i took it all apart to put in the new gasket set , and to have the guy tig weld on the inside and outside again after i cleaned it all up.

I might switch the piston and rings too , cause i noticed on the cylinder there are some small scratches going up and down , and i can feel them with my finger nail. compression before i took this apart was 145 +/- 3psi

Can those be removed with a hone ?

i'll get a pic.....brb

[Dirtcrasher]

Take it to a shop and let them measure the piston and the cylinder. Hones and rings can work in some cases but other times it really could use a bore and 1st oversize.

Cylinders wear egged shape and it's tough to see how worn it really is without a micrometer and inside telescopic gauge,

You've done this much work, get it checked out to be sure and the wear limits are in the manual you have.

[ThinktwiceZ71]

yeah i most likely will do that , just wish i could get it together as soon as my gasket kit gets here, but i am not going to do this half ass , i'll do it right the first time and hope i never have to do this again.

here is the pic of the cylinder , there is some discololring to 2 oppositce sides of the cylinder , like it's just been rubbing on those 2 sides over time.

[oscarmayer]

i am willin gto bet, your going ot have to have it bored to the enxt size. if your going to do a piston you have 2 options.
1-200x piston (mor ecompression than the stocker, size and only $49 on ebay for setup
2- weisco foreiged piston setup. more compression than any out ther and you can opt for a 12:1 if you so choose too instead of the 10.5:1 (requires 93 octane fuel minimum) costs $139 for a complete setup with top end gasket kit included

[ThinktwiceZ71]

what is the advantage for the wiseco piston vs a factory 200x piston ?

my machine ran great i thought with just the stock piston in it , so if i did bore it to the next size wouldn't the 200x factory piston be good enough for me ? I don't want a performance modded machine , i just want something that runs good , reliable and i won't have to sacrafice reliability for performance.

This engine ran great , and had 143 psi before i tore into this to replace the gasket in the crankcases. I will try to see if i can get the tools to measure and hope i can just get away with a hone job and new piston and rings , but if not i will bring it to a shop to get done right.

[maggiesboy]

bench shift it... you can spin the output shaft slowly while you run it through the gears..... looks good to the eyes though....good job on the manual like DC said.

[NINJA]

If your fingernail can catch those scratches a hone job is not the answer. Also, the wiseco 10.5:1 piston will give you better torque than stock but will be just as reliable as stock if clearance is right. BTW that tranny looks fine.

[Yamada]

Just read your comments on the pontiac 2.4l engine. We had to do the same job as you on my uncle's pontiac sunfire.grrrrrr... What a pain. Good parts is that the engine is still running

[ThinktwiceZ71]

yeah.....mine is too , pissed me off tho , i got it all up and running and then the next day the timing chain tensioner went on me , i had to tear it mostly all apart again to put a new tensioner in it , that was last summer and the car is still running like a dream.

that is my gas saver , for driving to and from work (pipefitter apprentice) and i save my 03 silverado stepside Z71 for play and show

[birddogg]

If you're a pipefitter, even being an apprentice, I'm sure you have the skills/mechanical know-how to finish this project without any issues.

Just go with an oversized 200x piston and if you can find a cheap 200x cam, throw that in while you have it apart. Wouldn't hurt to clean up the ports either.

I had a 200s years ago when I was growing up. Bought a beat-down 200x and combined the two.

[ThinktwiceZ71]

yeah , i called around today about getting the cylinder bored out to the first oversize , and everyone recommended 1 shop , they said they are the best around here and warranty their work 100%. I called the shop and they said to bring the piston and rings with the cylinder , and the instructions for them to set the clearances for the piston/rings to those instructions .

$20-$30 sounds like a good deal to me. I am leaning towards the wiseco piston , but am just afraid of all the people talking about cold seizures because they didn't warm the engine up enough , just how long do you wait ? i normally let my machine idle 2-3 minutes before i get on it anyways , but i mean is wiseco the best way to go , or is a honda 200x oem piston better ?