Barnboy's 1984 ATC200M Rebuild

[BarnBoy]

This thread is awesome

Nice work on the frame, sir!

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Thanks chop! It started out as just a simple rebuild, and has turned into a full blown restoration. It'll be one of a kind once I'm done, thats for sure!!

[BarnBoy]

You're lucky that the 200X splines are the same. When I made my ATC70 disc setup I just mounted a ATC70 drum in my lathe and turned it all off aside from the splines and made a shoulder on the hub. I welded on a flange and turned it straight in the lathe and found that an 82 250R disc was the perfect size.

I had some kind of NOS japanese caliper laying around and used that. If there's a will there's a way...

There's a dude on Facebook selling ATC 70 disc brake kits and he is charging almost 300$ and uses China brake parts

Yep, makes it much easier. I could have done it that way too but since the X is a bolt on thats the way to go.

If I can figure out a decent method of making my own carrier I could offer it as a product also, just have to see.

[ATC King]

It's looking good.


Building a carrier from scratch shouldn't be too difficult, especially with the tools and equipment you have access to. May be able to even build a few extra and see how quick you can sell them. I'm not worried about using Chinese brake calipers, and the one you're modeling it for has the OEM available if someone wants to shell out the cash. Either way, the Chinese copy and OEM Japanese calipers being available will give the buyer a lower cost option for completing the install.

I know switching my 185S to a hand operated rear disk has been a top mod. If the used 200X rear disks and hubs dry up though...

[ironchop]

...... I'm not worried about using Chinese brake calipers, and the one you're modeling it for has the OEM available if someone wants to shell out the cash. Either way, the Chinese copy and OEM Japanese calipers being available will give the buyer a lower cost option for completing the install.

...

I used the oem front caliper off a newer CR85 on the rear of my 200X. I paid $20 shipped for it(used in good shape, direct bolt-on)(I think they are Nissin brand) from that auction site, so there are still low cost options available even if you don't want Chinese stuff, for whatever reason.

Just throwing that out there for the folks who don't like Chinese stuff or don't like to spend a pile on an expensive brand new OEM caliper as an addendum to your post



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[BarnBoy]

It's looking good.


Building a carrier from scratch shouldn't be too difficult, especially with the tools and equipment you have access to. May be able to even build a few extra and see how quick you can sell them. I'm not worried about using Chinese brake calipers, and the one you're modeling it for has the OEM available if someone wants to shell out the cash. Either way, the Chinese copy and OEM Japanese calipers being available will give the buyer a lower cost option for completing the install.

I know switching my 185S to a hand operated rear disk has been a top mod. If the used 200X rear disks and hubs dry up though...

Yeah there's always the possibility they will dry up and then we'll just have to get creative. I had 3, sold 1 and keeping my last 2. 1 for this conversion and another for something down the road.

I may build a few extra. If I can source the right size tubing, itd be a simple matter of chop to length, bore ID for bearings, and make a little jig to weld the mounting brackets in. Voila. I have another idea to incorporate that I think would sell even better but I need to make 1 or 2 first.

[ATC King]

I used the oem front caliper off a newer CR85 on the rear of my 200X. I paid $20 shipped for it(used in good shape, direct bolt-on)(I think they are Nissin brand) from that auction site, so there are still low cost options available even if you don't want Chinese stuff, for whatever reason.

That's good to know. There'll also be rebuild kits/parts for those. The Chinese parts are pretty much disposable. Can't easily get rebuild parts for them or even be worth rebuilding by that time.

[BarnBoy]

That's good to know. There'll also be rebuild kits/parts for those. The Chinese parts are pretty much disposable. Can't easily get rebuild parts for them or even be worth rebuilding by that time.

But for $20, buy 3 and ride the rest of your life. I won't use a China master but calipers are cheap enough to have spares of, I dont see the point in rebuilding unless you have no other option.

[BarnBoy]

Over the holidays I got my forks rebuilt and finally finished....they're ready to go! I did a writeup on the process which I will link here, in case it decides to try and disappear on me again.

http://www.3wheelerworld.com/showthr...ebuild-writeup

Hope it helps someone out, I hadn't been able to find any info online about rebuilding these old school forks. I had hoped to document my engine rebuild and everything else im doing on the bike, but stuff happens, takes more time than anticipated and its a lot of time to to work, clean your hands, take a pic, then do something else, get all the oil off ya, repeat. But I know what it was like when I was starting out, so if I can put out any helpful info I'm happy to.

[MrConcdid]

Decaf? come on man, if your going to drink, drink the good stuff.
otherwise great thread and fork rebuild.

MrC.

[BarnBoy]

Decaf? come on man, if your going to drink, drink the good stuff.
otherwise great thread and fork rebuild.

MrC.

Haha, I dont drink decaf...I must have found the can somewhere and used it to store parts in. If I drink coffee its full strength and black.

I think only Yamaha riders drink decaf, least thats what I was told...

[DSHOT59]

You were told wrong.

[BarnBoy]

You were told wrong.

I suppose we can still be friends

Getting kinks worked out of my drawing, hopefully cutting brackets when I get a chance. Got a piece of tubing on order...crazy how expensive that stuff is. $40 for a 12" piece.

[BarnBoy]

Stuck at home thanks to a case of the rona, give me lots of time to catch up on small stuff that had been piling up everywhere.

Aaaaand, me telling myself "yeah, let's pull a part off this parts bike to use on my 200M, its in way better shape" turned into, let's hack this apparently rust free frame up and "fix it" lol. Turns out, it was actually pretty solid but theres no way of knowing until you cut it out. So, its all prepped and ready to go, im gonna turn some plugs in the lathe Thursday probably and weld er up Saturday. Side note, this bike ended up being very nice for what it was. One of my best scores, gave $25 for it. Frame is rust free, still has all the aluminum wire bands, all the vent hoses, thing thing had NEVER been apart before. But it sat outside for a while, so the seat pan is gone, tank is junk, etc. Im gonna make a frakentrike out of it, use the engine and other good parts from my rusted 185s, this good frame, etc and just make a solid rider out of used parts. Nothing fancy, other than maybe powder coating the frame.



It's the bike on the right, doesent look like much bit its a diamond in the rough.

Rusted 185s donor

[BarnBoy]

Should be able to turn a piece to fit in here and be good to go. I know its off topic from the 200M, but I'm waiting on parts for the M. Just thought I'd throw a few pics out there of another frame repair option in case it helps anyone new to this stuff.

[kb0nly]

Nice to see you are making progress to! I was just finishing up my 82 200E build today when i got asked to put a top end refresh on another motor for a guy, and then when i found out whats wrong with it i came post hunting because if i recall correctly you did a bushing on the cam journal in your 200M build didn't you? Browsed through the thread, saw pictures of it fixtured on the mill and after the machining, but i didn't see any pictures of how it turned out with the cam installed. How did you affix the bushing so it can't slide side to side or is it a tight fit when the rocker cover is torqued down?

I got a head coming to look at that has a badly worn cam journal, and i have a couple more in my spare parts bucket, i would like to start saving these if i can mill them and put in a bushing i just haven't been able to find any details of someone doing it. I have a mill and lathe at home so i can make and machine anything i want, just need some direction on how its being done, what bushing material was used, etc. I could easily fixture plate to my mill and run the boring head through to clean it up, i do a lot of small machining jobs like that.