1982 200e left crankcase cover and crankshaft bolt

[Fullsizechevy9]

Trying to get the cover off the one with the starter i got the pull start assembly off the starter is off took the pull start cage off that the dogs hit against and took all the bolts out holding the cover on still cant get the cover off idk if its because it looks like it been at the bottom of a mudhole and just living there or if im missing somthing looks like a seal in the cover shouldnt it just come off or do i need to take the bolt thats threaded into the crank shaft out and is it left handed threads or right heard somthing is left dont know what thanks

[350for350]

According to Partzilla, there's a couple of dowel pins at the back of the cover. These could corroded and not wanting to let the cover slide off. They also may just go into the sub trans cover and not all the way through. Try tapping gently with a rubber mallet or a dead blow hammer. This could help. It could also hurt ir you aren't careful.

[Fullsizechevy9]

I should have been more specific i got it to break loose all the way around kind of seems like the seal has it in the middle but the crankshaft spins freely or whatever is on the crankshaft that the seal is over spins freely thats what has me confused i have 1/8" gap all the way around but cant get it to come anymore i dont know if that bolt and washer that threads into the crankshaft has to come out first or not and i dont want to put an impact on it until i know if ita left or right hand threads

[Fullsizechevy9]

Wish i knew how to put up pics im on a phone not pc

[Fullsizechevy9]

On partzilla left crankcase cover/alternator diagram looks to me bolt number 18 has to come out for the cover to come off if i can figure out what the threads are i can get it out amd have a bettwr idea i tried but i cant get the crankshaft to stop spinning may have to jam.it up with a piece of wood but i still dont want to be turning the wrong way because everything has been tight on this motor because ita been outside for forever and i dont want to pull the threads

[Fullsizechevy9]

Ok i found a thread of a guy havin the same problem looked like thw thread was normal he didnt say it was left handed or anything amd seemes like he had to get that bolt out before the cover came off ill jam it up and give it another try tmrw or hit it with impact lightly and see if it budges

[barnett468]

keep us posted.

[Fullsizechevy9]

Will do:beer

[Dirtcrasher]

Wish i knew how to put up pics im on a phone not pc

I was the same way unti I downloaded Tap-A-Talk, now pics are chicken!!...

[Fullsizechevy9]

Ok ill do that i didnt think about that do you still have to use photobucket

[Shep1970]

On iPhone just click on the tree box while writing a post (top of page) another window will open click on choose photo then your library (your phone photos) choose your pic (one at a time) try to leave a space sopics aren’t merged. An upload box will appear/click it) it could take a second or 30secs depending on your signal strength. That’s all I do, it’s easy just be quick about loading pics there’s a time limit of sorts. Just try one pic and a sentence or two till u get the hang of it.

259224
No photo bucket- just your iPhone pics —-tap-a-talk I have no clue
Shep

[ps2fixer]

You could also try the gyazo app, it's like photobucket where they host the images and you post a link, or post the code to make the image show up full sized. This site supports uploading images, but not sure how it works via cell, tapatalk seems to be the go to way to use the site though via cell.

Pretty sure you have to remove the bolt and the part the bolt is holding on, haven't messed with the 200 series engines a whole lot and the 200es I think is slightly different.

To "lock up" the engine, pull the spark plug out and feed clean rope into the cylinder. The rope will take up more room than the combustion chamber which effectively locks the engine up much like hydro-locking an engine, but with rope. It's best to do this on the compression stroke so the valves are not opened.

Another route is to use some spare bolts, or maybe the recoil cage and use a pry bar to stop the engine from turning.

Or you could just cheat and use an impact driver, but you should torque it to spec when reinstalling.

[Fullsizechevy9]

Im going to use an impact so i dont take any chances messing anything up trying to jam it i have the whole top end off motor is at work and nobody is there on sundays for me to work on it i usually work on it after work during the week or saturdays also i have android i am about to try tap a talk

[Fullsizechevy9]

Im going to use an impact so i dont take any chances messing anything up trying to jam it i have the whole top end off motor is at work and nobody is there on sundays for me to work on it i usually work on it after work during the week or saturdays also i have android i am about to try tap a talkI figured it out dow loaded tapatalk thanks guys thats my bike $200 had a brand new oem carb on it when i bought it all i had to do was clean the tank good and it fired right up seems to be in pretty good shape motor wise ill get some pics of the spare 200e motor ill.be using the bottom end off of https://uploads.tapatalk-cdn.com/20190707/ed068d72935a183c887c01a8ff1d180e.jpg

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[ps2fixer]

Yep the photo worked =).

Yea if the top end is off, no reason not to use an impact. I'd say to do something to stop it and use a torque wrench to put it back on though. It's kind of like a lug nut for a car, you should have it close to spec. I've ran across too many people that thinks like 25ft/lbs is enough torque to hold a tire on (installed via 4 way).

[Fullsizechevy9]

Yep the photo worked =).

Yea if the top end is off, no reason not to use an impact. I'd say to do something to stop it and use a torque wrench to put it back on though. It's kind of like a lug nut for a car, you should have it close to spec. I've ran across too many people that thinks like 25ft/lbs is enough torque to hold a tire on (installed via 4 way).Ok good tapatalk makes it so easy i will be able to post pics of everything now i may start a build thread of teardowns and everything almost start to finish i was going to just get everything before i started but i cant help myself i love working on stuff and i plan on getting a good torque wrench and torquing everything to specs also thanks

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[Fullsizechevy9]

Ok good tapatalk makes it so easy i will be able to post pics of everything now i may start a build thread of teardowns and everything almost start to finish i was going to just get everything before i started but i cant help myself i love working on stuff and i plan on getting a good torque wrench and torquing everything to specs also thanks

Sent from my SAMSUNG-SM-N920A using TapatalkMan i seen a tri shee build a banshee motor would be awesome or one of the crf450r conversions they look so good would love to do somthing like that as a build after this build is finished this stuff is addictive

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[ps2fixer]

could always slap a 600rr engine in a 3 wheeler frame and call it a death machine lol.

https://www.youtube.com/watch?v=kvqeyxlkJp8

Or just double the size/hp lol

https://www.youtube.com/watch?v=4vj3qg2wtVo

Not sure how good that kind of setup would be on a 3 wheeler though, I could see maybe the 600rr + extending the swing arm some but you'd loose good turning etc more you extend it.

the 450r conversions come out well too.

There's also stuff in the 2 stroke world, like the 500R engine in a 250r frame.

https://www.youtube.com/watch?v=BRzytz_E6tw

[Fullsizechevy9]

could always slap a 600rr engine in a 3 wheeler frame and call it a death machine lol.

https://www.youtube.com/watch?v=kvqeyxlkJp8

Or just double the size/hp lol

https://www.youtube.com/watch?v=4vj3qg2wtVo

Not sure how good that kind of setup would be on a 3 wheeler though, I could see maybe the 600rr + extending the swing arm some but you'd loose good turning etc more you extend it.

the 450r conversions come out well too.

There's also stuff in the 2 stroke world, like the 500R engine in a 250r frame.

https://www.youtube.com/watch?v=BRzytz_E6twLol 600 may be to much a big 2 stroke in a 3 wheeler frame would be nice dont have to worry about riding wheelies to long like on this bike may be my next project a big 2 stroke in a 250r frame but im getting ahead of myself 1 project at a time a guy can dream though right these things seem like they are worse than a drug addiction

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[Fullsizechevy9]

Lol 600 may be to much a big 2 stroke in a 3 wheeler frame would be nice dont have to worry about riding wheelies to long like on this bike may be my next project a big 2 stroke in a 250r frame but im getting ahead of myself 1 project at a time a guy can dream though right these things seem like they are worse than a drug addiction

Sent from my SAMSUNG-SM-N920A using TapatalkThose 450r conversions look so good i like the modern look i dont race or mx so im sure it would handle good for what i like to do i just enjoy riding but they cost an arm and a leg to do

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[ps2fixer]

Yep, that's why I stuck with a 350x lol.

I have a kawa 350 big horn 2 stroke enduro motor that I'd like to throw in a 3 wheeler frame (200x, 350x, or 250r), just haven't ran across a rolller or parts machine yet. I don't need the biggest hp or anything, just something fun to ride =). 200 was a bit too small for me, I had 2 200x's and ended up selling them in favor of the 350x. I kind of viewed it as my 250sx was almost as fast as the 200x, and it's shaft drive, so mud etc isn't a problem. Wish there was more sport models made as shaft drive. They might be heavier, but not dealing with a chain would be nice.

I don't think I have a spare frame for a 250es/sx, but another interesting build could be to throw a TRX350D engine in one of those frames. The bottom end is very similar to the 250es/sx engines, but the top end is much like the 350x. I have one of those quads just because of the top end design. It's heavy as hell, but does ok, huge difference from a 350x. 350x is typically described as it does exactly what you tell it to do, extremely controllable etc. The TRX350D is described as a tank, it steers like a tank (horrible turning radius), it's heavy as can be like a tank, heck it even rides like a tank lol. It's a true work horse full time 4x4. One I have has a bent front swing arm or frame, so could be a fun build to swap it in a 3 wheeler frame.

[Fullsizechevy9]

Yep, that's why I stuck with a 350x lol.

I have a kawa 350 big horn 2 stroke enduro motor that I'd like to throw in a 3 wheeler frame (200x, 350x, or 250r), just haven't ran across a rolller or parts machine yet. I don't need the biggest hp or anything, just something fun to ride =). 200 was a bit too small for me, I had 2 200x's and ended up selling them in favor of the 350x. I kind of viewed it as my 250sx was almost as fast as the 200x, and it's shaft drive, so mud etc isn't a problem. Wish there was more sport models made as shaft drive. They might be heavier, but not dealing with a chain would be nice.

I don't think I have a spare frame for a 250es/sx, but another interesting build could be to throw a TRX350D engine in one of those frames. The bottom end is very similar to the 250es/sx engines, but the top end is much like the 350x. I have one of those quads just because of the top end design. It's heavy as hell, but does ok, huge difference from a 350x. 350x is typically described as it does exactly what you tell it to do, extremely controllable etc. The TRX350D is described as a tank, it steers like a tank (horrible turning radius), it's heavy as can be like a tank, heck it even rides like a tank lol. It's a true work horse full time 4x4. One I have has a bent front swing arm or frame, so could be a fun build to swap it in a 3 wheeler frame.Yes thats all i want dont need the biggest motor possible just somthing that is fun and possibly stand up on command lol wheelies are always fun about a 350 or 450 with reverse would be nice def want to do a 2 stroke build love the 2 strokes love the way they sound smoke and everything love the look of the expansion chambers got to have a good 2 stroke in the collection

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[ps2fixer]

The 200x's I rode didn't do wheelies as well as I hoped, but maybe the ones I rode were worn out junkers or something (I've rode 4 machines). They all felt too high geared, first gear barely gets the front wheel up. I did better wheelies on my 200ES popping it in gear. Both my 350x's wheelie 1st-4th pretty much at command. It's been a while since I've rode my 250sx, but I think it's 1st and 2nd it can wheelie and maybe 3rd if you rev it and pop it in gear. My cousin's 250sx wheelies like crazy though, but it has a 250es rear diff, so lower geared.

I'd wonder if the the china 230cc Honda clone engine cylinder would fit on an atc200x, turning it into a 230cc would help make some more power + the typical mods, higher compression piston etc. Who knows if the cylinder is much of any good, they are something like $75 new from china though.


I looked up the specs for the 250es/sx vs the trx350d and the hp difference is a bit, but the torque is much different.

250ES/SX
~18HP
13.7 ft/lbs of torque

TRX350D (I suspect similar specs for the 350x, but none posted in the service manual)
24.5HP
21 ft/lbs of torque

While I'm posting service manual based specs, here's the first gen 200x
~18HP
12.3 ft/lbs of torque

[Fullsizechevy9]

The 200x's I rode didn't do wheelies as well as I hoped, but maybe the ones I rode were worn out junkers or something (I've rode 4 machines). They all felt too high geared, first gear barely gets the front wheel up. I did better wheelies on my 200ES popping it in gear. Both my 350x's wheelie 1st-4th pretty much at command. It's been a while since I've rode my 250sx, but I think it's 1st and 2nd it can wheelie and maybe 3rd if you rev it and pop it in gear. My cousin's 250sx wheelies like crazy though, but it has a 250es rear diff, so lower geared.

I'd wonder if the the china 230cc Honda clone engine cylinder would fit on an atc200x, turning it into a 230cc would help make some more power + the typical mods, higher compression piston etc. Who knows if the cylinder is much of any good, they are something like $75 new from china though.


I looked up the specs for the 250es/sx vs the trx350d and the hp difference is a bit, but the torque is much different.

250ES/SX
~18HP
13.7 ft/lbs of torque

TRX350D (I suspect similar specs for the 350x, but none posted in the service manual)
24.5HP
21 ft/lbs of torque

While I'm posting service manual based specs, here's the first gen 200x
~18HP
12.3 ft/lbs of torqueMy 200s will pop up good in first and second i have to lean back when i hit the throttle to get it up and theres no getting it up in 3rd even throwing my weight back.while laying in the throttle. Does the yfz450 quads have reverse that seems like it would be a good powerplant for a build or possibly even a 4 to 3 conversion

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[350for350]

Lol 600 may be to much a big 2 stroke in a 3 wheeler frame would be nice dont have to worry about riding wheelies to long like on this bike may be my next project a big 2 stroke in a 250r frame but im getting ahead of myself 1 project at a time a guy can dream though right these things seem like they are worse than a drug addiction

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Oh no! These aren't illegal like a drug addiction!

[Fullsizechevy9]

Oh no! These aren't illegal like a drug addiction!Lol they will sure drain your wallet like one

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[ps2fixer]

Oh yea, the 3 wheelers are like a drug addiction, but it's more of a bug, once you catch it, it's hard to get rid of it. Before you know it, you have all storage areas filled with 3 wheelers and you're still looking for more.

[Fullsizechevy9]

Oh yea, the 3 wheelers are like a drug addiction, but it's more of a bug, once you catch it, it's hard to get rid of it. Before you know it, you have all storage areas filled with 3 wheelers and you're still looking for more.Just cant get enough working on them is just as fun as riding them knowing your the reason it runs as good as it does all while having a blast riding it is a good feeling

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[Fullsizechevy9]

Just cant get enough working on them is just as fun as riding them knowing your the reason it runs as good as it does all while having a blast riding it is a good feeling

Sent from my SAMSUNG-SM-N920A using TapatalkWas thinking maybe a z400 as a powerplant dont know much about them but they do have reverse and are chain driven

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[ps2fixer]

Are you able to kick a z400 (or 400z whichever way it is)? My aunt's boyfriend bought the z400 motorcycle new and bought it out to my mom & dad's place to break it in since they are from the city. Kick start only, and the guy couldn't kick start it to save his life. Not that he was small or weak or anything, not sure why he just couldn't get it going on his own. My dad had no problem. I couldn't start it either, but I was like 14? I didn't grow up on 2 wheels, so can't really comment on the power, but it seems to have plenty of compression lol. There was also a quad made with the same engine from my understanding.

The owner of the bike took it out back and got in some light mud, he goosed it too much and flew off the back and burned the inside of his leg on the exhaust, he ended up selling it as just someone taking over the payments lol. I think it was like $8k.

[Fullsizechevy9]

Are you able to kick a z400 (or 400z whichever way it is)? My aunt's boyfriend bought the z400 motorcycle new and bought it out to my mom & dad's place to break it in since they are from the city. Kick start only, and the guy couldn't kick start it to save his life. Not that he was small or weak or anything, not sure why he just couldn't get it going on his own. My dad had no problem. I couldn't start it either, but I was like 14? I didn't grow up on 2 wheels, so can't really comment on the power, but it seems to have plenty of compression lol. There was also a quad made with the same engine from my understanding.

The owner of the bike took it out back and got in some light mud, he goosed it too much and flew off the back and burned the inside of his leg on the exhaust, he ended up selling it as just someone taking over the payments lol. I think it was like $8k.Lol thats funny i had a z400 years ago i dont remember if it had kick start or not i always used the electric start it hauled ass would wheelie like no tomorrow guy i bought it from said it had work done to it not sure.if that was true but it would stand up in 3rd no problem just by the throttle i didnt have it long before i sold it it was a fun bike

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[Fullsizechevy9]

Lol thats funny i had a z400 years ago i dont remember if it had kick start or not i always used the electric start it hauled ass would wheelie like no tomorrow guy i bought it from said it had work done to it not sure.if that was true but it would stand up in 3rd no problem just by the throttle i didnt have it long before i sold it it was a fun bike

Sent from my SAMSUNG-SM-N920A using TapatalkOk i got the left crankcase cover off its cracked where a bolt goes through do you think i could weld it or jb weld it when i go back together with it when i tighten it up it should seal good with jb weld or high temp silicone that is if i cant find a cover for a good price hate to go back together with it and everything not be right i will add a pic also what do i need to remove the flywheelhttps://uploads.tapatalk-cdn.com/20190708/a5d48f7431d824969b03056f0ba0d444.jpghttps://uploads.tapatalk-cdn.com/20190708/cb68f64d721e36437262bd0cdeb857e1.jpg

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[Gabriel]

Not worth fixing.
Plentiful part.

The repair MIGHT hold. .....and it might not.

I looked, I only have one for an engine I intend to build someday but you can get one on ebay for $20, free shipping. I wouldn't be bothered for $20.


https://www.ebay.com/itm/Honda-ATC-200E-Big-Red-Stator-Cover-82-85/123761994035?fits=Make%3AHonda&epid=1423220973&_trkparms=ispr%3D1&hash=item1cd0ca2933:g:jIkAAOSwtItba2jV:sc:USPSPrio rityFlatRateBox!37062!US!-1&enc=AQADAAAB4KX%2FKt4E1xf3SDqEdBclaYYrCypVO%2Bka2C TfNJX2XbwNHNd3mrto%2BL8Newl5eEh6kiML7Ldo4U83p2hd7H d6brSzAtMPY3vWmAOZ9myG0hIeTBr4dfwmyrqXrOm%2BNfYO3U X9gaGpQNYVpkCreY1ZW7llbQfC3TE93rwk0p8aAQUg0wL6BEgP nBYuFvCOdFuzvJNM8ssLJh8p3C9mWTOmasw3paJE49chE6YsP2 mAyjnzCDshYPTDPbkByRcPHBgSltGhaMgz9nZqyv%2BUI3rmlV jIHQNnG59pFNTlPy1a6E2f3G09BSbpyto%2B5mMyAg7K2401Qw tXgAxzQO%2BUP3v3kkIItv3ktarRhBG0XmLKk7wfEP2v4VFMnt fxcCSKfVZzfVgbpeAFVDtIhcTmf%2FGyffavs38p%2BMDPGICL FUco2KQxWDJvgzc%2Ftdy31jzIvQpmXdu%2F6%2FJi3BU8qAvM e3dFZXR7Ct5M%2FA9r1lbYeQAyPlF9acmKYXxOfPn6gesQABgJ X31zJMXOd3AYNdGy6MIHJsYAK%2Bqa4cUs18Wh8VCvbzLZ0CHM femj7WiGtGga1C5OCpJWFaSIqB3re8jRBQIy0yZG%2BxlL55EA IsnqL1Y29JJhov8PRRy67DGMA42SjNDuMg%3D%3D&checksum=12376199403546a1d846e52f40448e55c222b7101 575

[Fullsizechevy9]

Not worth fixing.
Plentiful part.

The repair MIGHT hold. .....and it might not.

I looked, I only have one for an engine I intend to build someday but you can get one on ebay for $20, free shipping. I wouldn't be bothered for $20.


https://www.ebay.com/itm/Honda-ATC-200E-Big-Red-Stator-Cover-82-85/123761994035?fits=Make%3AHonda&epid=1423220973&_trkparms=ispr%3D1&hash=item1cd0ca2933:g:jIkAAOSwtItba2jV:sc:USPSPrio rityFlatRateBox!37062!US!-1&enc=AQADAAAB4KX%2FKt4E1xf3SDqEdBclaYYrCypVO%2Bka2C TfNJX2XbwNHNd3mrto%2BL8Newl5eEh6kiML7Ldo4U83p2hd7H d6brSzAtMPY3vWmAOZ9myG0hIeTBr4dfwmyrqXrOm%2BNfYO3U X9gaGpQNYVpkCreY1ZW7llbQfC3TE93rwk0p8aAQUg0wL6BEgP nBYuFvCOdFuzvJNM8ssLJh8p3C9mWTOmasw3paJE49chE6YsP2 mAyjnzCDshYPTDPbkByRcPHBgSltGhaMgz9nZqyv%2BUI3rmlV jIHQNnG59pFNTlPy1a6E2f3G09BSbpyto%2B5mMyAg7K2401Qw tXgAxzQO%2BUP3v3kkIItv3ktarRhBG0XmLKk7wfEP2v4VFMnt fxcCSKfVZzfVgbpeAFVDtIhcTmf%2FGyffavs38p%2BMDPGICL FUco2KQxWDJvgzc%2Ftdy31jzIvQpmXdu%2F6%2FJi3BU8qAvM e3dFZXR7Ct5M%2FA9r1lbYeQAyPlF9acmKYXxOfPn6gesQABgJ X31zJMXOd3AYNdGy6MIHJsYAK%2Bqa4cUs18Wh8VCvbzLZ0CHM femj7WiGtGga1C5OCpJWFaSIqB3re8jRBQIy0yZG%2BxlL55EA IsnqL1Y29JJhov8PRRy67DGMA42SjNDuMg%3D%3D&checksum=12376199403546a1d846e52f40448e55c222b7101 575No $20 im def buying another not taking that chance wasnt sure how plentiful they were thanks

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[Fullsizechevy9]

No $20 im def buying another not taking that chance wasnt sure how plentiful they were thanks

Sent from my SAMSUNG-SM-N920A using TapatalkAbout to start ordering the bearings amd what not for the bottom end kind of want to go with a better clutch and stiffer springs probably barnett discs with vesrah springs

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[Fullsizechevy9]

About to start ordering the bearings amd what not for the bottom end kind of want to go with a better clutch and stiffer springs probably barnett discs with vesrah springs

Sent from my SAMSUNG-SM-N920A using TapatalkI heard of sombody having trouble with the wiseco piston with wrist pin seizing because they dont put an oil galley for oil to get to it for lubrication like the oem honda has is this true i would think a company like wiseco would have all that figured out

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[Fullsizechevy9]

I heard of sombody having trouble with the wiseco piston with wrist pin seizing because they dont put an oil galley for oil to get to it for lubrication like the oem honda has is this true i would think a company like wiseco would have all that figured out

Sent from my SAMSUNG-SM-N920A using TapatalkAlso could i make a puller for the flywheel somthing to thread into it and push against the bevel on the crankshaft to push it out or is there an easier way

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[barnett468]

I heard of sombody having trouble with the wiseco piston with wrist pin seizing because they dont put an oil galley for oil to get to it for lubrication like the oem honda has is this true i would think a company like wiseco would have all that figured out


That would be highly unusual and unlikely in a low performance app, however, if you are going to loose sleep over it, you can easily add a channel in the wrist pin hole with a small triangle file, plus you can drill a small hole (around 1/8th") in the wrist pin boss from the inside of the piston then put a small chamfer on it.

[Gabriel]

Also could i make a puller for the flywheel somthing to thread into it and push against the bevel on the crankshaft to push it out or is there an easier way

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MUCH easier way. Go to your local auto parts store....get a lug for a late model Volkswagen. Not a lug nut, a lug stud. Those goofy Euro-trash style male lugs. The VW is the proper threads. Turn in by hand then just gently bump it with an impact and be sure to have your hand under the flywheel. It'll cost you a whopping $3 or so.
This is what you want...

https://www.autozone.com/suspension-steering-tire-and-wheel/wheel-stud/dorman-wheel-stud-610-318-1/156506_220034_0

[ps2fixer]

Jump on ebay and look up a flywheel puller for your machine. They are normally pretty cheap too, so much easier to use the right tool than trying to make something else work.

The 200E/ES parts are very plentiful, they were the most sold machines in USA, there's something like 300k+ of them in the USA.


Oh for whatever you use for the puller, throw a little grease on the threads to prolong the tool's life.

[Fullsizechevy9]

I may add a couple holes to be on the safe side i plan on running the piss out of it i also made a puller before i seen any of your replys should work pretty goodhttps://uploads.tapatalk-cdn.com/20190708/0a81dcb647ae375adaf067efebe726cc.jpg

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[Fullsizechevy9]

Jump on ebay and look up a flywheel puller for your machine. They are normally pretty cheap too, so much easier to use the right tool than trying to make something else work.

The 200E/ES parts are very plentiful, they were the most sold machines in USA, there's something like 300k+ of them in the USA.


Oh for whatever you use for the puller, throw a little grease on the threads to prolong the tool's life.Glad they're pletiful ill be buying a new stator cover and i have plenty of anti seize for bolts its some good stuff also will need to get a new starter and solinoid possibly the regulator rectifier is there somthing i can buy to test it

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[Fullsizechevy9]

My puller worked like a charm also hit it lightly with impact and came right off

[Gabriel]

All there is to it. You will need a totally different puller if you ever get into a dry stator engine like the 200S. But what you have works for E & ES ...and maybe M, I never had one apart...yet.

Pretty simple.

[Fullsizechevy9]

I can make anything i need took me about 30min to make that one might need to invest in a good slide hammer to pull some of these bearings out

[Fullsizechevy9]

I can make anything i need took me about 30min to make that one might need to invest in a good slide hammer to pull some of these bearings outAre the bearings and seals on partzilla good quality they seem to have just about everything i will need for this bottom end all my bearings are in good shape but while i have it down no sense in not changing thw

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[ps2fixer]

Also same type of puller (not sure if same size) as the 350x uses. The home made puller looks fine, is it made of mild steel? Ideally you'd probably want it hardened a little so it lasts longer, but then again, having it a softer material will let the tool get torn up before the threads/crack.

What's wrong with your starter? You'd probably be better off putting new brushes in the OEM one and greasing it back up if it's in otherwise good shape instead of buying the china ones on ebay. I don't know how close of a clone they are, but the china ones could be handy for parts for the OEM starters, just be sure to use quality brushes, bearings (if there are any), and don't forget they need at least a little grease.

Same goes for the solenoid, they are super heavy built, the 1000cc side by side engines uses the same solenoid with some different wiring. I saw some photos of someone that took apart their solenoid and it looks like it's fairly easy to do, could take it apart and clean up the heavy copper connections with some fine sand paper (like 200+ grit)

Solenoid is still available from Honda, but it's got a price tag too. The cheap ones on ebay are china made, if they don't have good quality copper connections, there's comments that they tend to get stuck "on" aka the arc is welding the contact together. If you wanted to try to go a little cheaper, I can buy a solenoid for a much newer Honda and modify the wiring, probably be around $40.

https://www.partzilla.com/product/honda/35850-958-680?ref=25aa28c55d690fb8d33fda96bb49546677d3b089

Regulator/rectifier is out of production, only the ATC200E is the same part number (200ES is probably similar though). Test process for it is pretty simple, take a multi meter and read the DC volts of the battery with the engine off. Fire up the engine and check the next reading. It should be higher voltage than the first. After a long enough ride so the battery is fully charged etc, it shouldn't go over 14.5-15v at higher rpm. The rectifier part of it is just to convert AC to DC, so reading a voltage increase at all shows it's working, that part very rarely fails. The voltage regulator part of it is where it can fail and cause it to take out batteries by overcharging them. Pretty sure it's semi rare for them to fail. I've only seen one bad one in my life, but it's from a china quad, so hard to compare it to Honda lol.

[Fullsizechevy9]

Also same type of puller (not sure if same size) as the 350x uses. The home made puller looks fine, is it made of mild steel? Ideally you'd probably want it hardened a little so it lasts longer, but then again, having it a softer material will let the tool get torn up before the threads/crack.

What's wrong with your starter? You'd probably be better off putting new brushes in the OEM one and greasing it back up if it's in otherwise good shape instead of buying the china ones on ebay. I don't know how close of a clone they are, but the china ones could be handy for parts for the OEM starters, just be sure to use quality brushes, bearings (if there are any), and don't forget they need at least a little grease.

Same goes for the solenoid, they are super heavy built, the 1000cc side by side engines uses the same solenoid with some different wiring. I saw some photos of someone that took apart their solenoid and it looks like it's fairly easy to do, could take it apart and clean up the heavy copper connections with some fine sand paper (like 200+ grit)

Solenoid is still available from Honda, but it's got a price tag too. The cheap ones on ebay are china made, if they don't have good quality copper connections, there's comments that they tend to get stuck "on" aka the arc is welding the contact together. If you wanted to try to go a little cheaper, I can buy a solenoid for a much newer Honda and modify the wiring, probably be around $40.

https://www.partzilla.com/product/honda/35850-958-680?ref=25aa28c55d690fb8d33fda96bb49546677d3b089

Regulator/rectifier is out of production, only the ATC200E is the same part number (200ES is probably similar though). Test process for it is pretty simple, take a multi meter and read the DC volts of the battery with the engine off. Fire up the engine and check the next reading. It should be higher voltage than the first. After a long enough ride so the battery is fully charged etc, it shouldn't go over 14.5-15v at higher rpm. The rectifier part of it is just to convert AC to DC, so reading a voltage increase at all shows it's working, that part very rarely fails. The voltage regulator part of it is where it can fail and cause it to take out batteries by overcharging them. Pretty sure it's semi rare for them to fail. I've only seen one bad one in my life, but it's from a china quad, so hard to compare it to Honda lol.

I could harden it but it worked pretty good I would rather the threads be soft and strip on that versus the harder to obtain part. The starter wasnt with the motor when it was given to me so i will have to find a good used one maybe. The solenoid is there along with the rectifier/ regulator so maybe they will be ok not sure it was out in the weather for a long time. I was hoping they had new ones that were decent that way when i got to the point of starting the motor i didnt have to find one then wait kind of nipping it in the bud. I will be having you make me a new harness so i will know all is good there could probably just use the old harness but like i said i would feel better if it were new so i dont have problems later down the road less to go wrong and easier to narrow things down if somthing does go wrong. Plus would be more customized to my bike since its shorter than the 200e frame probably not enough to matter much but i will have the battery, solenoid, and rectifier/regulator in a different spot than on the e and the 200x light on the front but ill cross that bridge when the time comes i guess. I will get a multi meter when i go get other tools i need like a blind hole bearing puller and hone might just order all that online.
Are partzilla bearings and seal of good quality that you know of will probably order everything i can from there. The bearings are good honestly but i see no reason not to change them while im there. I will be tearing down the crankshaft assembly also connecting rod seems like it may be out of specs side to side will see when i get there. Will probably just order everything i think i will need from looking at the diagram and go from there ill finish tearing everything down once i get most of my parts.

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[Fullsizechevy9]

I could harden it but it worked pretty good I would rather the threads be soft and strip on that versus the harder to obtain part. The starter wasnt with the motor when it was given to me so i will have to find a good used one maybe. The solenoid is there along with the rectifier/ regulator so maybe they will be ok not sure it was out in the weather for a long time. I was hoping they had new ones that were decent that way when i got to the point of starting the motor i didnt have to find one then wait kind of nipping it in the bud. I will be having you make me a new harness so i will know all is good there could probably just use the old harness but like i said i would feel better if it were new so i dont have problems later down the road less to go wrong and easier to narrow things down if somthing does go wrong. Plus would be more customized to my bike since its shorter than the 200e frame probably not enough to matter much but i will have the battery, solenoid, and rectifier/regulator in a different spot than on the e and the 200x light on the front but ill cross that bridge when the time comes i guess. I will get a multi meter when i go get other tools i need like a blind hole bearing puller and hone might just order all that online.
Are partzilla bearings and seal of good quality that you know of will probably order everything i can from there. The bearings are good honestly but i see no reason not to change them while im there. I will be tearing down the crankshaft assembly also connecting rod seems like it may be out of specs side to side will see when i get there. Will probably just order everything i think i will need from looking at the diagram and go from there ill finish tearing everything down once i get most of my parts.

Sent from my SAMSUNG-SM-N920A using TapatalkI think i will be calling my build the 200sex s frame and top end e bottom end and x front end

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[Fullsizechevy9]

I think i will be calling my build the 200sex s frame and top end e bottom end and x front end

Sent from my SAMSUNG-SM-N920A using TapatalkThats 200 s.e.x. by the way not 200sex......lol

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[ps2fixer]

Partzilla doesn't make bearings, they are a dealership of many brands. If it's bearings based on the OEM part numbers, it should be the exact same bearing that the engine came with. If it's aftermarket, then it's whatever aftermarket brand it is. Generally speaking, for a Japanese machine you'll want to stick with Japanese branded bearings (NSK and such).

[El Camexican]

Generally speaking, for a Japanese machine you'll want to stick with Japanese branded bearings (NSK and such).

Why is that?

[Fullsizechevy9]

Partzilla doesn't make bearings, they are a dealership of many brands. If it's bearings based on the OEM part numbers, it should be the exact same bearing that the engine came with. If it's aftermarket, then it's whatever aftermarket brand it is. Generally speaking, for a Japanese machine you'll want to stick with Japanese branded bearings (NSK and such).They claim its oem parts but dont show a brand

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[ps2fixer]

Why is that?

I guess it's more personal preference. I wouldn't buy USA made bearings for a Honda, and China quality isn't exactly the greatest. What other country makes good bearings?

[El Camexican]

They claim its oem parts but dont show a brand

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I've seen "OEM" bearings come direct from the dealer in branded boxes that were from different manufactures.

NSK while originally made in Japan are now manufactured all over the globe as are most other famous brands. In my opinion any bearing with a known name on it is going to be fine. SKF, FAG, TIMKIN, KOYO, NSK, NTN, NACHI etc. If the part number crosses over you're good to go.

What you want to avoid are the no name Chinese bearings that sell for a fraction of the cost of name brands that sometimes come from Bearing Boss, or All Balls type seller. I don't have an issue with using them for non-engine applications, but for crankshafts and transmissions I stick to the pricier name brands.

For the record I'm not knocking the eBay bearing sellers, some of the stuff they sell is impossible to find elsewhere.

[El Camexican]

I guess it's more personal preference. I wouldn't buy USA made bearings for a Honda, and China quality isn't exactly the greatest. What other country makes good bearings?

Made in J.A.Pan was a joke prior to the 70's. Now it's replaced Made in Germany as the mark of quality for imports, but today factories like NSK have plants in India, Germany, England and yes even China. It's not about the country of origin, it's about what materials and tolerances are specified and who's doing the Q.C. at the plant. Plenty of crappy bearings made in China, but they aren't made at the same plants as the brands we're familiar with.

[ps2fixer]

Yea, I guess my wording was a bit off, I prefer Japanese brands as in the HQ is in Japan. Like a Toyota Tundra is built in Texas, USA, but it's a Japanese truck to me. I'd think it's designed in Japan, but I wouldn't know for sure. I agree though, known brands of being high quality should be fine. Likely one of them is the OEM brand anyway.

Kind of like for Japanese engines run NGK or Denso spark plugs, matching Japanese design spark plugs to Japanese engines. Same goes for Ford, run Motorcraft plugs in a Ford engine, I guess it's more about sticking to what was used as OEM over cost savings of other brands.

[ironchop]

......, but today factories like NSK have plants in India, Germany, England and yes even China. .....

And America.... Specifically near where I grew up in Franklin Indiana.

So there, Mr Mexican Smarty pants [emoji23][emoji23][emoji23]

https://uploads.tapatalk-cdn.com/20190709/6f060f4afde3f005739d43fc30cf82c1.jpg

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[El Camexican]

Sorry, I lost my bearings while racing to look for locations. Thanks for having the balls to update my post.

[ironchop]

Sorry, I lost my bearings while racing to look for locations. Thanks for having the balls to update my post.1)Where has Tripledog been hiding?

2) what was this thread about, again?

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[ironchop]

Yep yep yep yep yep yep yep yep yep yep ......fart ......yep yep yep yep yep yep yep yep yep yep yep !:Bounce:Bounce:Bounce:Bounce:Bounce:Bounce:Bounce :Bounce:Bounce:Bounce:Bounce:Bounce:Bounce:Bounce: Bounce:Bounce:Bounce:Bounce:Bounce:Bounce:Bounce:B ounce:Bounce:Bounce:Bounce:Bounce:Bounce:Bounce:Bo unce:Bounce:Bounce:Bounce:Bounce:Bounce:Bounce:Bou nce:Bounce:Bounce:Bounce:Bounce:Bounce:Bounce:Boun ce:Bounce:Bounce:Bounce:Bounce:Bounce:Bouncehttps://youtu.be/qnb0yfzPHjE

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[Fullsizechevy9]

Does anybody know the size and thread pitch of the exhaust flange bolts on the 200 e or s or x i think they are all the same

[Fullsizechevy9]

Going to have to try and drill and tap these cant get them out tried heat tried welding a nut to what was sticking out nothing they are in there and arent budging

[Fullsizechevy9]

I know its 6mm just not sire of the thread pitch 1.5mm maybe?

[Fullsizechevy9]

You know what im just going to drill and tap it to the next standard size i have everything here i need wont have to go buy anything

[Fullsizechevy9]

Bike my s also has a broke exhaust studhttps://uploads.tapatalk-cdn.com/20190709/dc62f580c7ff2c69170e462c945e40e0.jpg

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[Fullsizechevy9]

Yep yep yep keep bounce bounce bouncing and fart fart farting on that dick dick dick you rode in on:Bounce

[shortline10]

Next time cut the nut off before breaking the stud .
A quality dermal disk will remove the nut quickly .



Bike my s also has a broke exhaust studhttps://uploads.tapatalk-cdn.com/20190709/dc62f580c7ff2c69170e462c945e40e0.jpg

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[Fullsizechevy9]

Ice ice hoe

[Fullsizechevy9]

I got it broke off like that tried heat they wouldnt budge then welded a nut to what was sticking out not much maybe half inch and they wouldnt budge like that either

[Fullsizechevy9]

Studs were real corroded hardly any threads left on what was sticking out i guess the exhaust flange got loose and they tried tightening it both studs were broke off when i got the motor

[Gabriel]

Yeah they can be a pain sometimes. It's really never a good idea to thread ferrous and non-ferrous materials together, but companies continue to do because it's fast and easy.

Patience. You'll get it.

[Fullsizechevy9]

Wouldnt have cost much to put 2 stainless studs in it i guess over and over again it was much cheaper for them but im going back with stainless and plenty anti seize

[Fullsizechevy9]

Wouldnt have cost much to put 2 stainless studs in it i guess over and over again it was much cheaper for them but im going back with stainless and plenty anti seizeWould yall recommend taking a few thousenths off this head its kind of pitted in 1 area where it seals just enough to clean it up no more than .005https://uploads.tapatalk-cdn.com/20190709/a7e4efc608eb54f71bf264d162e5c386.jpg

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[Fullsizechevy9]

Would yall recommend taking a few thousenths off this head its kind of pitted in 1 area where it seals just enough to clean it up no more than .005https://uploads.tapatalk-cdn.com/20190709/a7e4efc608eb54f71bf264d162e5c386.jpg

Sent from my SAMSUNG-SM-N920A using TapatalkGot the exhaust studs drilled and tappedhttps://uploads.tapatalk-cdn.com/20190709/9b909799e0730df6c2a21a17ba35a81d.jpg

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[Gabriel]

Nice. ....even nicer to have space and equipment. I miss working in a machine shop some days. Been a long time since I used a Radial Arm Drill like that one in the back.

It wouldn't hurt to resurface the head. Minimal clean up. Depending on how bad it is, you may be able to just lap that much out. **PISSED** I used to have a lapping plate made from heat treated CPM10V and Blanchard ground surface. No idea what happened to it OR the one I made from Meehanite.

[Fullsizechevy9]

It rarely gets used im on that big lucas boring mill behind it all the time luckily they dont mind if i squeeze stuff for myself in every now and then or i can just stay after work and do what i want. I will probably just mill a few thousenths off it then might lap it in if i want to get that serious with it have to see if we have any lapping plates that will work we have a lap machine but i.dont think it would work to good with anything that isnt round its a lapmaster

[Fullsizechevy9]

What would be the best way of getting the dowel pins out the top of the head they are in there pretty good and its a blind hole pretty much dont want to mess them up or warp the head with to much heat i could just use some 1 2 3 blocks to mill it but i am thinking about going ahead and lapping all sealing areas