MISC Part Measurements

[ps2fixer]

Been planning to make a thread for measurements on parts for a while. I'll try to keep the first couple posts as a sort of index to posts. Feel free to post measurements/images too. Probably best to do one post per part to make it somewhat easy to find. Preference is accurate measurements from a caliper or similar tool, but rough measurements with a tape measure won't be turned down =).

If there's a measurement you could use for a part I have, post or pm me for it. If I still have the part I'll grab the measurement.

[ps2fixer]

1984 TRX200 Dash

Choke cable mounts in the center.
Ignition switch hole is 32.1mm (larger size like atc250es/sx uses)
Handle bar bolt width pattern is 100mm by 32mm
Upper cover bolt holes are 60mm apart
Neutral/Reverse light housing screw holes are about 55mm apart at an angle.

[ps2fixer]

86-88 TRX200SX (photos are of an 86)
86-87 ATC125M

Bolt holes to mount the dash are 100mm apart
Ignition switch hole is around 26.5mm (this one is worn a bit so a little hard to be sure what the size is exactly)
Neutral/Reverse light housing screws are 40mm apart

[ps2fixer]

1979-1980 ATC110 Stator/Alternator
PN: 31102-943-004

Power output spec 6V 43w @ 6,000 RPM (Machine uses 6V 25W headlight + 6V 3W tail light no voltage regulator)

Overall diameter - 130mm
Mounting bolt pattern has 6 holes, the ATC110 used 3 of them. Measuring straight across center to center it's 114mm, going from one bolt to another how it was mounted on the 110, it's about 98.8mm.
Hole for the rotor is roughly 80.65mm
Thickness where the bolts go though - 18mm
Bolt hole size - 6.55mm
Wire length - about 6in from the grommet (152mm)

Markings of interest: 37000, 0950 9H

Wire connectors
Yellow - 3.5mm Bullet Female
Black - 3.5mm Bullet Double Female

As tested with my multi-meter
Yellow to Ground - 0.3ohm
Black to Ground - 3.7ohm

[ps2fixer]

33700-965-003 Tail Light Assembly

84-86 ATC200S
83-85 ATC200X
83-86 ATC250R
85-86 ATC350X

Bolt hole mounting width - ~170mm (caliper doesn't go this big)
outer lip of light chamber (width) - 151.6mm
outer lip of light chamber (height) - 41.2mm
white plastic overall height - 51mm
white plastic overall width - 198mm

[Gabriel]

This will be a work in progress. Edited multiple times.

Parts marked !!!!!!! Indicate my part was damaged a difficult to read/measure. DO NOT accept my information on these AND anyone who KNOWS, please chime in and help me get it correct.

I also have a difficult time measuring worn out O-rings. I've noticed some commonality in several. I just imagine the wear is giving me different readings BUT there's very few actual size variations.

Engine serial number- TBO5E-5164794

200E bottom end seals & bearings

***Sub transmission cover***
---Bearing - NTN-6202-Japan-KS-----OD=35mm ID=15mm Width=11mm
---Bearing - NTN-6203-Japan-JU------OD=40mm ID=17mm Width=12mm
---Shift drum seal - E17-SD-12-22-5-----OD=22mm ID=12mm Width=5mm


***Left side case cover***
---Main Seal - FPJ-45-60-9-HS-85-----OD=60mm ID=45mm Width=9mm
!!!!!---Neutral indicator shaft seal-----NGK-17 OD=16mm ID=8mm Width=6.5mm!!!!


***Left side case spacer***
---Bearing - Japan-KX-NTN-6302-----OD=42mm ID=15mm Width=13mm
---Seal - A13-SD-36-50-9-HS-----OD=50mm ID=36mm Width=9mm
!!!!!!!!O-ring ----- OD=13mm ID=11mm Width=2mm!!!!!!!
---Inspection/timing plug O-ring ----- OD=24mm ID=18mm Width=3mm

***Left side crankshaft bolt***
--- O-ring ----- OD=11mm ID=8mm Width=2mm


***Right side case cover***
---Bearing - NTN-japan JU-6203 ----- OD=40mm ID=17mm Width=12mm
---O-ring for dipstick ----- OD=24mm ID=18mm Width=3mm
---O-ring for clutch adjuster ----- OD=11mm ID=8mm Width=2.5mm

[Gabriel]

200E Bottom continued...

Repeating myself, These o-rings are difficult to measure because of the sad shape they are in. Do not take the measurements as absolute fact.


***Clutch Basket Bearing***
---Koyo - Japan - 16003 OD=35mm ID=17mm Width=8mm


***Oil Centrifuge O-ring***
---OD=20mm ID=17mm Width=2mm


***Left Side Main Case***
---Bearing - NTN-Japan-6202Z OD=35mm ID=15mm Width=11mm
---Bearing - Japan-JU-NTN-TM?204 -? Could be a B or an 8, I cannot tell- OD=47mm ID=20mm Width=14mm
---Seal - HS-A3-SD-30-40-9 OD=40mm ID=30mm Width=9mm
---Seal - N17-SD-14-28-7-A OD=28mm ID=14mm Width-7mm
---O-ring for oil passageway to sub-transmission OD=12mm ID=7mm Width=2mm !!!Very difficult to read, crushed flat.
---O-ring for Neutral light switch OD=10mm ID=7.5mm Width=2mm


***Right side main case***
—-Bearing- JU-INA-NTN-HK-1512V2 Od=21mm ID=15mm Width=11.9mm
—-Bearing- Japan-NSK-6006 OD=55mm ID=30mm Width=13mm

***OIl Pump O-Rings***
—-OD=14.5mm ID=9.5mm Width=2mm


***Crankshaft bearings***
—-Japan-KA-NTN-63/28 VII - OD=68mm ID=28mm Width=18mm

***Starter Gear Cage Bearing***
--- OD= 26.0mm ID= 20.00mm Width= 16.65mm

***Pulse Rotor Spacer***
---Seal K14S-15-25-7
OD=25mm ID=15mm Width=7mm

[ps2fixer]

Might be worth while posting the year of the 200e, the 82 could be different from the 83, unless you ran though the part numbers to validate they are identical. Grabbing the engine number would probably validate the year better than the frame since the engines are swapped around fairly often.

[Gabriel]

Ok. Added that to original post. Anyone know how to determine exact year? The frame it was removed from had no neck sticker.....well, not enough left to read.

[ps2fixer]

Grab the engine number
82 should be TB05E-50xxxxx
83 should be TB05E-51xxxxx

[Gabriel]

Ok. That should be every seal and bearing in the bottom end except the rod bearing. Haven’t had a chance to press that apart yet.
Only other thing I missed was the drain plug O-ring. Not a difficult item to get so...

Now, to start getting new ones and get this engine built.

[Gabriel]

Added a seal and a bearing I missed!

[BarnBoy]

Ok. That should be every seal and bearing in the bottom end except the rod bearing. Haven’t had a chance to press that apart yet.
Only other thing I missed was the drain plug O-ring. Not a difficult item to get so...

Now, to start getting new ones and get this engine built.

Very helpful....thanks for posting!!

[Gabriel]

BigRedMark over at Just Big Reds forum said I could post this link.

VERY good info. Decal locations for the 200ES. Not just locations but actual MEASUREMENTS. Awesome. This will get updated from time to time until complete.
Thank you Mark.


http://forums.justbigreds.com/post/1...pid=1307987900

[Dirtcrasher]

I think we tried something similar before, gotta find a better way to keep it organized or it's a cluster fluck...

PS2, you're good with Data/speadsheets!