rdlsz24
03-23-2012, 09:48 PM
This procedure should apply to all 185 and 200 Honda trikes besides the 86-87 200x
I see questions come up about this every so often so I figured since I was going to be doing it I would document the process.
The first step that I don’t even have pictured here is to get your piston to TDC. If you don’t have the cam installed yet the exhaust and compression stoke hasn’t been determined so just have the T on the flywheel showing through the viewing hole. I usually remove the spark plug and look in the hole with a flashlight to verify the piston is at the top of its stroke.
If you do have the cam installed then to make sure you are on the compression stroke of TDC you still want to have the T showing, but you also want both rocker arms to be loose. This means if you remove the valve access caps on the head cover you can move the arms just a tiny bit.
Ok so now we have the piston at TDC. To make sure it stays there through the procedure, I always use my ½ ratchet on the end of the crank and put the handle resting against my work bench. If you don’t do this the piston tends to want to move back down in the cylinder.
http://img.photobucket.com/albums/v603/rdlsz24/ATC200x/DSCF4100.jpg
Whether you are just now installing the cam or already have it installed, it will have the lobes pointing down at this point and the little dowel pin should be pointing to about 11 o’clock. Now you are ready to install the cam chain onto the cam gear, and the gear onto the cam. Install the gear onto the cam with the little o pointing to 12 o’clock. At first you might get off a tooth or 2 and have to try again. Keep at it until you get the o pointing to 12.
http://img.photobucket.com/albums/v603/rdlsz24/ATC200x/DSCF4103.jpg
Next install the pulse generator base. The only thing to watch out for here is to not mess up the oil seal when slipping it over the little pin.
http://img.photobucket.com/albums/v603/rdlsz24/ATC200x/DSCF4104.jpg
Now you are ready to install the pulse rotor. The little slot on the backside of the rotor will fit over the dowel pin on the cam. This is the only way it can install so it’s hard to mess up. It will point slightly to the left of 12 o’clock when installed.
http://img.photobucket.com/albums/v603/rdlsz24/ATC200x/DSCF4108.jpg
Finally it’s time to install the base plate. Before doing this you want to turn the crank so you get the F on the flywheel showing through the viewing hole. The F is about ½ inch to the left of the T on the flywheel. Do the same thing with the ratchet against the bench to make sure the piston doesn’t move again. Align the vertical line on the little black plastic box on the base plate with the vertical line on the rotor. They should both be pointing at about 12 o’clock. Tighten the screws.
http://img.photobucket.com/albums/v603/rdlsz24/ATC200x/DSCF4109.jpg
That’s really all there is to it. If you had the cam out you will want to adjust your valves, and you will want to adjust the cam chain if you slackened it to install the cam gear.
Any questions or corrections, please post them up.
Rob
I see questions come up about this every so often so I figured since I was going to be doing it I would document the process.
The first step that I don’t even have pictured here is to get your piston to TDC. If you don’t have the cam installed yet the exhaust and compression stoke hasn’t been determined so just have the T on the flywheel showing through the viewing hole. I usually remove the spark plug and look in the hole with a flashlight to verify the piston is at the top of its stroke.
If you do have the cam installed then to make sure you are on the compression stroke of TDC you still want to have the T showing, but you also want both rocker arms to be loose. This means if you remove the valve access caps on the head cover you can move the arms just a tiny bit.
Ok so now we have the piston at TDC. To make sure it stays there through the procedure, I always use my ½ ratchet on the end of the crank and put the handle resting against my work bench. If you don’t do this the piston tends to want to move back down in the cylinder.
http://img.photobucket.com/albums/v603/rdlsz24/ATC200x/DSCF4100.jpg
Whether you are just now installing the cam or already have it installed, it will have the lobes pointing down at this point and the little dowel pin should be pointing to about 11 o’clock. Now you are ready to install the cam chain onto the cam gear, and the gear onto the cam. Install the gear onto the cam with the little o pointing to 12 o’clock. At first you might get off a tooth or 2 and have to try again. Keep at it until you get the o pointing to 12.
http://img.photobucket.com/albums/v603/rdlsz24/ATC200x/DSCF4103.jpg
Next install the pulse generator base. The only thing to watch out for here is to not mess up the oil seal when slipping it over the little pin.
http://img.photobucket.com/albums/v603/rdlsz24/ATC200x/DSCF4104.jpg
Now you are ready to install the pulse rotor. The little slot on the backside of the rotor will fit over the dowel pin on the cam. This is the only way it can install so it’s hard to mess up. It will point slightly to the left of 12 o’clock when installed.
http://img.photobucket.com/albums/v603/rdlsz24/ATC200x/DSCF4108.jpg
Finally it’s time to install the base plate. Before doing this you want to turn the crank so you get the F on the flywheel showing through the viewing hole. The F is about ½ inch to the left of the T on the flywheel. Do the same thing with the ratchet against the bench to make sure the piston doesn’t move again. Align the vertical line on the little black plastic box on the base plate with the vertical line on the rotor. They should both be pointing at about 12 o’clock. Tighten the screws.
http://img.photobucket.com/albums/v603/rdlsz24/ATC200x/DSCF4109.jpg
That’s really all there is to it. If you had the cam out you will want to adjust your valves, and you will want to adjust the cam chain if you slackened it to install the cam gear.
Any questions or corrections, please post them up.
Rob