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 ). 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 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.
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

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

Dennis kirk's Vesrah complete gasket kit: $38.99
Honda dealer unknown brand gasket kit: 46.95$CAN
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...

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.

[Yamada]

Canadians...

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.

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~it...1~1002~H833426

Best deal I found.