200x frame gussets

[tricycle tommy]

I’m restoring a 200x frame to ride next year. I got an 83 frame and then ended up getting a 85 frame as well looking for some parts. Since I’m blasting and powder coating the frame, I’m just going to fix and coat both of them, maybe build another wheeler or just sell the frame.

Anyway, I made sleeves for the front necks with some scrap DOM roll bar tube. I have seen a couple builds here where they also did the frame junction behind the swing arm. Is there anything else I should do while I’ve got it on the bench? I’m not racing or jumping it, just a kinda old guy trail riding with the boys in the NH woods, but I want to ride this for a while and not have to pull it back apart every winter.

Working on a battery box now, I’ll figure out how to post pictures and make a build thread at some point.

[oldskool83]

the only thing that breaks on them is the down tube over time, a long gusseted wrapped around will help. There is a missing gusset on the left foot peg area. The stupid foot pedal on motor and frame wear out something bad. You need to grind the weld on the backside of the frame to remove the foot peg slug and replace with a new one. If you cant make it JRtrikesports sell them to weld back in.

https://www.jrtrikesports.shop/collections/atc-350x/products/honda-atc-350x-foot-peg-replacement

If your going that far you better fix everything worn out. The frames always bend at the rear to one side. That's due to crashes, no gusset in the world fixes that, but you need to address is. I'd highly invest in swapping foot petal designs so you do not wear out the engine casting anymore. Here's mine. I like to remove the dumb sheet metal lower frame gussets and have tubing put in. You do not need that upper chain roller. It's honestly pointless, just the bottom one.

I use a atc200s foot pedal and cut it up until it met OEM location dimensions and cleared everything. Master cylinder I use trx450r and made bronze bushings with a grease fitting so it can never wear out. Not like OEM steel on steel. This also stopped the brake line over the exhaust which can melt away. This all is one of the biggest fails on the 200x, plus the axle set up and kicker gears. Rest of the toy is pretty good. Oh throw the seat latch away, just rubs the frame away.

[Scootertrash]

the only thing that breaks on them is the down tube over time, a long gusseted wrapped around will help. There is a missing gusset on the left foot peg area. The stupid foot pedal on motor and frame wear out something bad. You need to grind the weld on the backside of the frame to remove the foot peg slug and replace with a new one. If you cant make it JRtrikesports sell them to weld back in.

https://www.jrtrikesports.shop/collections/atc-350x/products/honda-atc-350x-foot-peg-replacement

If your going that far you better fix everything worn out. The frames always bend at the rear to one side. That's due to crashes, no gusset in the world fixes that, but you need to address is. I'd highly invest in swapping foot petal designs so you do not wear out the engine casting anymore. Here's mine. I like to remove the dumb sheet metal lower frame gussets and have tubing put in. You do not need that upper chain roller. It's honestly pointless, just the bottom one.

I use a atc200s foot pedal and cut it up until it met OEM location dimensions and cleared everything. Master cylinder I use trx450r and made bronze bushings with a grease fitting so it can never wear out. Not like OEM steel on steel. This also stopped the brake line over the exhaust which can melt away. This all is one of the biggest fails on the 200x, plus the axle set up and kicker gears. Rest of the toy is pretty good. Oh throw the seat latch away, just rubs the frame away.


Thanks!! thread stashed in my "ATC Mods" folder. :naughty::D

[tricycle tommy]

Thanks oldskool83. Very helpful stuff, I should be able to cover it all.

Is it necessary to cover the entire front down tube like in your picture? One of my frames is cracked, I’m going to weld it before I sleeve over it. I made a sleeve that’s about 6 inches long and cut to go around the studs and bottom frame junction.

The cracked frame is also bent at the back slightly like you said. The other one is straight, I am making a battery mount behind the air box, had to make sure it was straight to start with.

The foot peg mounts appear to be fine on this one. I was planning to make the brake chassis mounted so I’ll have more engine options. Are you saying to change the pegs themselves as well?

I’ll cut the chain roller bracket and other gusset off and use a corner plate or tube there, no problem.

For the seat latch, I did see some mods that used a pin and retainer clip. I have a good latch so I was going to use it but didn’t know it would be a problem.

[oldskool83]

You do not need to weld it all the way like I had mine done. HREatv.com did mine and this was the 2nd idea he had. The 1st time he stopped a few inches above the bottom bolt mount area.

[tricycle tommy]

Got my frame(s) stripped down and sent off to sand blasting. Made a battery box that mounts behind the air box as well. I need to find some picture hosting and I’ll upload some progress pictures. Should have them back on the fab table in the next couple of weeks, get the new metal welded on and then take them to my buddy’s place for powder coat.

Oldskool, what pegs are in your pics? I think I’d like to have the ramp up on the outside like that.

Tore down the second swinger over the weekend, those front bearings are a pain in the ass. I am going to add a grease fitting on the tube when I put it back together, or maybe just make some Delrin bushings on the lathe unless that’s a bad idea for some reason.

[tricycle tommy]

I’m getting it blasted before I weld stuff to the frame and then again before coating if needed. I made my parts already, I just didn’t want to TIG weld new steel onto dirty metal. I’ll only need a little bit of time to weld everything on and I can do it at the shop where I’m coating it as I have one of my welders there. This is a trail rider toy, I’m not trying to restore it to new condition and show it off.

I understand how a build works and I’m not a rookie, I build race cars for a living and I’ve had lots of fabrication projects in my time. I’m just not familiar with all the specifics of the ATC as I haven’t owned one in my adult life.ive got my own auto/fab shop and also weld at my friends shop so I’m not building this in some home garage or leaving it out in the weather while I build it.

[tricycle tommy]

Looks like a post got deleted, my last one was a reply to that.

[oldskool83]

Rob wicks at wicked metals makes all my pegs. Your can buy directly from him.at wicked metals.com stock is all junk by now.