1983 ATC 200 Restoration and Parts (New Pics)

[larryhorne]

I've been reading many of the posts regarding restoring these older trikes and I have a few questions for anyone interested in entertaining them.

I've had a 1983 Honda ATC 200 (note sure if this is all of the model number due to "over spray" on the tag) stored for several years. It looks like a basket case but it was running when I stored it. I would like to get it out and see if I can get it back into operation so that I can ride with my daughter (age 6) who has a new 4 wheeler.

When I stored the trike, it was running strong but needed a muffler and some clutch work. The clutch would slip if you didn't "baby it" into gear.

I'm going to pull it out of storage this weekend and see if I can get some of the paint overspray off of it. It was stored in the corner of a bay in our garage we use as a paint area.

My questions are:

1) I'm certain its a 1983. How do I determine the exact model?

2) I'm looking at a couple of used exhaust systems on ebay. What years will fit this 1983?

3) I called my local Honda shop and they were less than helpful once I gave them the year and model. Where online can I find good replacement components for both engine and frame?

4) Are there any "obvious" issues these bikes had during this year that I need to be mindful of during the restoration?

Again, the bike looks a lot worse than it is but I'll know more this weekend once I get it home.

Thanks for your patience and I appreciate any information you may be able to provide.

Lar

[ikester1]

:beer Hi Larryhome! I have a 1985 200s. If you only have a pull start it's most likely an "S" If it has electric start also it could be an "E". Go to Bike Bandits and key in your year for OEM replacement parts and by the diagrams they give you you should be able to figure it out!
Have fun and get her goin!
The Ikester

[sandpuppi101]

A picture is worth a thousand words around here!!!

[atctim]

If it for sure a 1983 and it is a 200 - it could be one of three models (By Honda):

#1 - ATC200 - pull start, front suspension only....
#2 - ATC200E Big Red - Electric start would give this away
#3 - ATC200X - front and rear suspension.

I picture it in my head to be a Honda ATC200 from all you have said.......

Does it look like this:

http://www.venustel.com/~tkeister/2001.jpg

They are great bikes and super simple to work on. there are thousands of people on this site ready and willing to help you out.

1) I'm certain its a 1983. How do I determine the exact model?
A - a picture would be best, otherwise go to
http://www.3wheelerworldforums.com/Brochures/ATCsite/
and click on 1983 and browse.

2) I'm looking at a couple of used exhaust systems on ebay. What years will fit this 1983?
A - If your bike is identified as an ATC200 then1981 thru 1983 will fit perfect.....also 1981 thru 1983 ATC185S will fit. With a small bit of retro-fitting, 1984-1986 ATC200S will fit as well (all models I mentioned have the exact same head pipe and heat shield)

3) I called my local Honda shop and they were less than helpful once I gave them the year and model. Where online can I find good replacement components for both engine and frame?
A - You will find many Honda Shops will shy away from 3 wheelers - this is because most of the staff are part of the brainwashed sheep heard - LOL. The classifieds here and Ebay are extremely valuble resources.

4) Are there any "obvious" issues these bikes had during this year that I need to be mindful of during the restoration?
A - Not really - these are really rock solid trikes. The only thing I have some across on these machines has been human stupiduty - IE welding shiters to shift shafts, welding hubs to axles - and the like.
WELCOME to the boards!

[hondaatcvabeach]

If it is a 200s or 200e he wouldn't have a clutch correct? Must be a 200x

[hondaatcvabeach]

Hey Larry when you get it going you should meet us up at Slades in Surry Co. some time.

[ATCR250R]

Yes, I think now it can be clear to you that a full clutch operated 200 with full suspension is a 200X. Another easy way to tell the model is the vin number that can be found on the neck of the frame up front. Also to be sure its a 1983 the 10th letter should be D.

[atctim]

If it is a 200s or 200e he wouldn't have a clutch correct? Must be a 200x

An ATC200 and 200E both have clutches (2 each as a matter of fact), but they are not manually operated. Automatic Clutches can slip too.

[rally4x4racer]

how long was it sitting? If it has been sitting a long time you might want to dump some oil in the plug hole and let it soak it up while you are working on it... ( dont try to start it right off)

I just started working on one that sat so long the crank and rod assy is frozen!!

I am going to toss it in a bucket of gas for a while and then try it.... maybe toss it in a bucket of oil for a few days to see if there is any hope.

[hondaatcvabeach]

An ATC200 and 200E both have clutches (2 each as a matter of fact), but they are not manually operated. Automatic Clutches can slip too.



Yea you are correct but how could you "Baby" a centrifical clutch into gear?:wondering

[larryhorne]

ATCTIM's pic is it.

OK, I'll post pics this weekend once I haul it out of the garage, there is 5-6 years of stuff in the way of getting to it. Included are restored tractor and lawn tractor. I'll try to remove some to the overspray so not to emabrrass myself too much, it looks worse than it is.

I stopped in last night and looked at the frame for VIN, no luck, tires are flat and I cannot manage to remove enough of the overspray to see it. The year infor is pain, "ATC200 1983 Model 9/82".

I'll defer looking for ebay and other used parts, muffler especially until I get confirmation on it being a straight 200.

Stay tuned guys, I'll be needing your assistance very soon.....my daughter is already planning ride trips!

Thanks

Lar

[larryhorne]

Well I got the ATC 200 home Saturday. Here are the Pics.

Thanks to John in VA Beach, I have a muffler which I installed today.

The bike has been stored for at least 10 years. I did nothing in way of prep prior to storing.

Got it home, pulled the plug, poured in about 4 ounces of Marvel Mystery Oil and let it set while I aired up the tires. The font tire has a hole in it that 5 plugs will not stop........anyway I decided to pull the starter.

First time it about pulled my arm out of joint. I assume the compression release did not work......after putting my elbow back in place, I pulled her again and she fired right up! Old gas and all........


Well, I need to change the oil but I put 1 hour on it today. Idles rough but I'll pull the carb soon and see whats up there....gotta fix the front tire, may try tube, the front shocks seem to bottom out easily???????? John graciously provided me replacement fenders, one of mime is cracked very bad, I'm going to "plastic weld" the cracks in the front fender. http://www.urethanesupply.com/ATVwelder.html

Since it seems to run ok, I guess once cold weather hits her in VA I'll tear it down and recondition the paint on the frame.


BTW, any secrete to removing the front wheel assembly?

Lar

[larryhorne]

Ok, the ATC 200 (1983) is coming apart. See Pics. I decided to disassemble it when I discovered the front wheel bearings and brakes were toast.

Before I discuss the obvious broken parts,let's talk about engine overhaul. Just prior to this the bike started smoking a little, well it is 24 years old. Should I invest the money and how much in overhaul of the engine or at least a top end? I

OK, there was not that much broken. The biggest problem I see is the chain adjustment bolt has been broken for some while....see pic of chain. The chain looks ok but a part up around the small sprocket is worn. All of the cables have deteriated rubber boots? Not sure worth replacing entire assembly. Front and rear brakes. Will check rear bearings. Will overhaul the carb. Front tire needs replaced or a tube. I'll take the tires off the rims and paint, replace valve stems. A couple or return springs need replacing. The switch assembly is hosed up, corroded.....the front brake handle assembly need replacing.

What about decals? Can I get new replacements? If so I'm going to paint the tank. Should I seal the tank? Its not leaking but its off the bike now.......

Oh, I wish someone had told me about the 21 top and 21 bottom bearings in the front fork assembly...............I learned of the total number at 1230 at night. I had 41 accounted for and went looking for the last one.....found it....HAHA!

OK here are the pics.....

[larryhorne]

Here is what it looks like now.

[edog]

Coming along good!!!!!!!!

What are your plans for the motor?

[ATC-Eric]

Ok, the ATC 200 (1983) is coming apart. See Pics. I decided to disassemble it when I discovered the front wheel bearings and brakes were toast.

Before I discuss the obvious broken parts,let's talk about engine overhaul. Just prior to this the bike started smoking a little, well it is 24 years old. Should I invest the money and how much in overhaul of the engine or at least a top end? I

OK, there was not that much broken. The biggest problem I see is the chain adjustment bolt has been broken for some while....see pic of chain. The chain looks ok but a part up around the small sprocket is worn. All of the cables have deteriated rubber boots? Not sure worth replacing entire assembly. Front and rear brakes. Will check rear bearings. Will overhaul the carb. Front tire needs replaced or a tube. I'll take the tires off the rims and paint, replace valve stems. A couple or return springs need replacing. The switch assembly is hosed up, corroded.....the front brake handle assembly need replacing.

What about decals? Can I get new replacements? If so I'm going to paint the tank. Should I seal the tank? Its not leaking but its off the bike now.......

Oh, I wish someone had told me about the 21 top and 21 bottom bearings in the front fork assembly...............I learned of the total number at 1230 at night. I had 41 accounted for and went looking for the last one.....found it....HAHA!

OK here are the pics.....


She apears to be in really good shape! :beer With the little bit of elbow grease, and work you plan to put in it, she will be good as new!

Heres the only decals I could find on ebay, there for an 84, Even if their not the same, it would look good.

http://cgi.ebay.com/ebaymotors/1984-Honda-ATC-200S-gas-tank-decals-stickers_W0QQcmdZViewItemQQcategoryZ43975QQihZ011Q QitemZ320074825059QQrdZ1QQsspagenameZWDVW

I would suggest you seal the tank. Check around the bottom corners for rust or corrosion on the outside. With it sitting that long with gas, you could have some problems you dont know about yet. Check into some tank sealent, people around here can give you some good suggestions on brands.

For the bearings, theres a guy on the boards here that makes them, there real good I have been told (as well as decently priced). Just dont buy the generic ebay ones! His name is "Dads" shot him a pm for some good bearings.

On the engine rebuild, I would say its worth the investment. The 200's are tanks. It just goes to show that it sat for 10 years, and fired on the second pull! You really cant break them unless you neglect them for a LOOOOONG time.

And those bearings can be a pain. I too had to learn the hard way :lol: If you dont already have a manual for it, I would suggest you get one. You can download one from here:

http://www.3wheelerworldforums.com/showthread.php?t=56218&highlight=trike+manuals

They ask for a small donation to keep the site up. I got one, printed it and threw it in a three ring binder. Cheap and effective. I would also suggest a new front tire, you wont regret it. Cables, wires, and brake pads are easily found on ebay at a decent price.

Good luck, and keep us posted! :beer

[hondaatcvabeach]

Wow Larry you are going down to the frame. I bet it will look good when you are done. I have seen replacement decals on ebay, next time I come across them I will forward you the link. I just got back into town yesterday. I will stop by my parts bike this week and grab that trunk for you. Good luck!

[larryhorne]

Here is the link to the Stuck Axle..... http://www.3wheelerworldforums.com/showthread.php?t=63604&highlight=200+restoration

I made a separate posting (hoping for more reads) regarding the stuck rear axle....I've already messed up slightly, as in minor damage to the threads on the axle.....they were covered in grease and I banged them with a hammer trying to free the axle, then I broke a hardened steel center punch off in the end of the axle so that a cotter pin will not go thru now...........oh and not to mention the 4 drill bits broken trying to drill it out......

Anyway, I think I have all the retainers off but the rear axle will not come out....is it just the two locking nuts holding the brake drum and axle on??

Recommendations??

Lar