Barnboy's 1984 ATC200M Rebuild

[BarnBoy]

Well it's still in progress....I need to get my rear in gear. Had some hangups with the valves/seats as a result of a dumbazz machinist. Came close to ruining the head but found a guy worth his salt who was able to save it. Anyway just waiting on painting the decompression lever, then that goes in along with the timing chain, side cases etc. Then likely painting the motor, still figuring that out. Here's where I sit now.

Also picked another 84....this time with 4 wheels. Probably my issue is that I work multiple projects lol. Gotta focus!!!

[BarnBoy]

Man its been a while since I updated this thread. Got the engine together, all I gotta do is adjust the clutch and then paint it.

Started on the rear disc brake comversion...should have that welded out and finished this week. Then its time to tear down and send stuff off to the powdercoater (frame, bearing carrier, racks, hitch, etc) Also thinking of getting the hardware replated if i can find someone local.

Making progress slowly but surely. I'm gonna get this thing finished....its been way too long. Time to quit messing with other projects and buckle down on this till its done. Goal is to have a mechanically 100% like new bike, with some improvements.

[ATC King]

Here's some pictures of how I mounted the XR600R front caliper.



If I do another one, I'll do a little more clearancing in some areas, less removal of the old brake housing in others, and build smaller caliper brackets or add some holes to lighten them (just because).

In the pictures, I'm just using a bearing race as a spacer for the rotor during the build process, because that's what I had laying around and the rotor was on and off several times during the build. I used washers for final assembly. I also had the advantage of the master cylinder already being hooked up, so I could lock the caliper to the rotor to hold it centered and in place, which made lining up and tack welding the brackets easier.

[BarnBoy]

Thanks King, appreciate that. I like how you pegged that lower mount through the drum brake cam bore. But I agree with lower profile mounts lol, lots of extra steel. But thats ok. Check out what I came up with, not finished yet just got the lower mount tacked on tonight. Got the height of the pads on the rotor pretty well perfect, also as square to the rotor as possible. Full floating caliper so it does have some room for error. Made sure I had free play both ways on the slides too.

I will likely box in the mount to the housing....I'd like to be able to do it differently but the carrier housing is such i think this makes the most sense. No chance of warpage this way either.

Can't wait to actually be able to stop!!!

[ATC King]

Can't wait to actually be able to stop!!!

No doubt. I had actually planned to add a disc brake to the front too, but after years of riding with drum brakes, and seeing how effective this is with a hand lever, I'm stopping with the rear.

The front disc parts went onto my YTM anyway, so not waste there.

[daddy420big]

i been wanted to do this to my 200m that iam lifting for the rear . someone should come out with a kit that are made for the hardtails

[BarnBoy]

No doubt. I had actually planned to add a disc brake to the front too, but after years of riding with drum brakes, and seeing how effective this is with a hand lever, I'm stopping with the rear.

The front disc parts went onto my YTM anyway, so not waste there.

Front disc would take some engineering but definitely doable. Ive always had good luck with the front brakes, just the rears always sucked. Ive actually been able to score a NOS NASA axle for this build so I'm going to get that, mount my rotor in my modified housing and ensure everything is still square. Then I will finish welding it out.

I need to paint my motor yet and its been frustrating trying to find a decent paint to use. But once I do that I'm going to finish the tear down for powder coat.

[Jwheeler]

Front disc would take some engineering but definitely doable. Ive always had good luck with the front brakes, just the rears always sucked. Ive actually been able to score a NOS NASA axle for this build so I'm going to get that, mount my rotor in my modified housing and ensure everything is still square. Then I will finish welding it out.

I need to paint my motor yet and its been frustrating trying to find a decent paint to use. But once I do that I'm going to finish the tear down for powder coat.

Lane where did you find a brand new NOS NASA super axle from ? You need to post pics .

[BarnBoy]

Lane where did you find a brand new NOS NASA super axle from ? You need to post pics .

From another cool guy I met on the forum....wait I think it was you Jwheeler!! Lol Thanks again man, I'll definitely post up some pics.

Side note to anyone else looking for parts, Jwheeler has been excellent to deal with.

[BarnBoy]

Well, been doing a bunch of work on the 200M this week. Got the motor painted with vht universal engine aluminum enamel paint. No primer.....hopefully it holds up ok. Looks great though, the can says to bake in an oven but since I can't do that I ran a heat gun over it for about an hr. Should at least help it cure up some.

Then I turned my attention to the chassis. First bad news....my NASA axle doesent fit my modified disc brake housing. Apparently the 200M housing is different. This was a spare i had and it looked them side by side I can see the difference now. Live and learn.

Went through the fiches on Partzilla and found EVERY SINGLE bolt, nut, screw, and washer for this machine. I then cross referenced that over to Belmetric and placed an order. So I have all brand new zinc plated hardware on the way.

I got the frame stripped down, only to find a small soft spot. Ok, no biggie I'll cut it out and plate it and be good to go. Start scraping crud out of the footpeg mounting plate, and realize....oh shiit. Completely rusted through. Theres ontario salt and years of moisture and muck being trapped in there for ya. Pull it out again tonight to start wire brushing some of the crud off the rest of the frame. I find that the whole gusset plate behind the lower rear motor mount is rusted out, along with the tubes inside. So i now have a dillema....do I cut it out and fix or source a mint frame from somewhere. Gonna be a lot of cutting and fabbing which I'm plenty capable of. Its just idk what else ill run into. I need to make sure the rest of this thing is rock solid.

But hey, the NOS Nasa axle fits my 200M housing!!! So i got that goin for me......lipstick on a freakin pig at this point ��

















First lil soft spot discovered...





Simple wire brushing revealed....







And before anybody says.....parts trike! Shut up, not gonna happen lmao. Im talking to you ATC King 😆. But I do appreciate your insight if you have any, or know of a good frame.

...........but man I do question at times......what the heck am I thinking. Just more money! Right!? Ugh

[BarnBoy]

Stripped everything off the frame and washed it today. Im probably going to attempt a repair, I just don't know how far its rusted. There may be sectioned of rusted tube that look fine on the outside but are almost rusted through inside. Will likely need to build a jig to mount the frame in if i repair or even cut into it. Metal has a way of twisting and springing when you cut apart a piece such as a frame. Especially with as much as I will need to cut out.

I wish i had space in the garage to weld....I would build a jig and just fab my own frame. Not this time I guess, maybe a good idea for that rusted 185s I have. Full suspension, thicker steel, make it to where a plastic 200 seat pan can be used....that would be cool.

[BarnBoy]

Drawing some guessets and stiffeners in Cad to plasma cut and weld on to the frame.

[Dirtcrasher]

That motor paint came out great Lane...

[BarnBoy]

That motor paint came out great Lane...

Thanks Steve, next time I talk to you ill tell ya about it. But overall pretty happy. Next is the black side covers, then the motor is done.

[ATC King]

And before anybody says.....parts trike! Shut up, not gonna happen lmao. Im talking to you ATC King ��.

I mostly say that for people wanting to flip these things, but in your case...wowzers, good luck with that one. I'll definitely appreciate seeing what your solution is.

I understand the amount of work that goes into something like that.



Keeping the foot peg area clean is a real PITA though. It's a big muck trap. I'm surprise more of them aren't rusted out in that area.