Rebuilding 200 engine

[Nick_R_23]

Hey everyone Im getting ready to tear down my '83 200 engine, I miss riding it too much lol. This is gonna be on a budget, mainly just to fix whats wrong. From what I remember a few months ago, I think the timing chain jumped a few teeth (wasnt completely sure), it lacked serious power, and a clunking was coming from the bottom end (?), but it was hard to tell really where it was coming from. It also had a couple of small leaks around gaskets and seals due to age and lack of use.

I was thinking of getting a set of rings, maybe piston if it was bad, gasket + seal kits, do something to the clutch if it needs it, and fix whatever was making that clunk noise. Is there anything I need to look at or replace while its apart? Or any ideas what is making the clunk noise?

I also remember that the flywheel nut kept coming loose, so im afriad the keyway might be wallowed out. Will i need a new crank if this is the case?

Thanks in advance for all your help, this really is a great site!!!! :w00t:

-Nick :TrikesOwn

[TravEX]

Sounds like you will need to tear it down first and see what you need. A manual makes it easy, hope you got one.

[jason 32]

yep find out whats wrong -
crank might need to be rebuilt- not that much -
hone the cyl - check the piston to cyl clearance,
lapp the valves---
use a good moon key-tighten it with a impact--- use red thread locker--(lock tight)
youll need a new timing chain -
and tensioners!! - you dont want it to jump out of time again do ya?
let us know whats all wrong when you get it tore apart

[Nick_R_23]

A manual makes it easy, hope you got one.

Yah I got one laying around somewhere, but Im not sure what kind it is, if i can find it.

Ill be taking it out of the machine later this week cause I dont feel like going outside in the garage right now and moving all the trikes into the shed outside in -20 degree windstorm. (i have to reassemble my dads big red first :rolleyes: ) Plus the 200 doesnt have rear wheels so ill have to take it apart in the shed which isnt insulated :cry:. Neither is the garage so thats not much better. I miss our nice warm shop. :lol: Although ive had to do worse so ill stop complaining.

On the crank, im worried about having to replace it cause i think the keyway is screwed beyond repair, and the only place I can get one is from some idiot who wants 100$ for 1/2 an engine thats been sitting outside for 10 years. He doesnt even know if the part I need on it is good. Who else sees a great deal in there? :crazy:

And the reason the timing chain jumped was because before we got the manual (after the machine died) we didnt know how to check the slack so i think it just got loose and jumped.

-Nick :TrikesOwn

[Mobular]

Replace your cam and piston with 200X pieces. They are comparable in price, and will give you a nice bit of added performance.

[Nick_R_23]

Whats the difference between 200 and 200x cam and piston? And what year x would I use them from?

-Nick :TrikesOwn

[jaykup]

Whats the difference between 200 and 200x cam and piston? And what year x would I use them from?

-Nick :TrikesOwn

the 200x piston is a higher compression piston.. I would recommend just getting a new High-Compression Wiseco Forged Piston. I got one and it works wonderfuly. It raises the compression from a stock 7.8 or 9.6 with the X to 10.25:1 and is forged. You can also go any oversize you want. From std to 2mm.

http://cgi.ebay.com/ebaymotors/HONDA-ATC200-WISECO-PISTON-KIT-50MM-OVER-ATC-200-81-85_W0QQcmdZViewItemQQcategoryZ43977QQihZ002QQitemZ 4620031454QQrdZ1QQsspagenameZWD1V

The same guy carries other sizes. Its very affordable. The 200x cam may have a better lift on it, but I don't know for sure. Check ebay for a NEW cam.. I bought this one from this person. Its a "mild" cam, I don't know the specs for sure. It probably won't require stronger valve springs, but it would be recommended to at least replace the ones you have.

http://cgi.ebay.com/ebaymotors/81-83-ATC200-Camshaft-Hi-Performance-Cam-ATC-200_W0QQitemZ260053141958QQihZ016QQcategoryZ43977Q QssPageNameZWDVWQQrdZ1QQcmdZViewItem

It says only 81-83 but WebCamshafts go on a much larger range, so I believe it will fit almost any 200. Looks like 79-85 is your ticket. Anything over 86 may need a different cam than that one.

Just a good way to go, you are only up to about 150 dollars plus a bore (about 40-50). Wiseco Forged pistons are far better than OEM Cast ones too.

Also, I had the same problem with my 200 with the flywheel coming loose. Get a nylon lock nut (of course) and some RED Loc-tite. That will hold it for sure. Hopefully your key is still use-able, but if it is too far gone, you will need to either replace your crank or get it welded / machined. A used crank from ebay is far cheaper.