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Thread: 85 ATC200X rebuilt

  1. #1
    Join Date
    Apr 2025
    Location
    Corpus christi, Tx.
    --
    6

    85 ATC200X rebuilt

    I just finished rebuilding and 85 ATC200X that my boss gave me. My daughter and I did it together. We did a complete restoration with all new bearings, new forks and lots of other new NOS parts that I got lucky finding.
    The engine got a new, NOS Honda cylinder with a wiseco.10.25:1 piston. I reground the seats and replaced the guides myself. I also had to make a couple new busings for the transmission and replace most of the thrust washers. All new honda clutch parts. It's a good solid engine but I spent way more than it's worth probably. It should last another 40 years for my kids at least.
    I have a question though. I rebuild engines all day every day but it's been 30 years probably since I did one in a bike with a wet clutch. A shimmer of aluminum in the oil is pretty normal for these right? Im assuming it's clutch. Everything is adjusted by the book, no unusual noise and it runs like a scalded dog. Just wanted to make sure.https://youtu.be/c-HDyENO3_8?feature=shared
    Last edited by M14dan; 04-13-2025 at 09:41 AM.

  2. #2
    Join Date
    Apr 2025
    Location
    Corpus christi, Tx.
    --
    6

  3. #3
    Join Date
    Jul 2009
    Location
    South Florida
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    6,778
    Sounds healthy .
    I have rebuilt hundreds of these motors .
    Aluminum debris in the oil is definitely not normal .
    Maybe a little after the first oil change .
    These motors will give the oil a grey look when it’s clutch debris.
    I would just change the oil a few times with a few heat cycles and see if it clears up .
    Something might be a little too tight or oil delivery to the head is lacking .
    Did you make sure the rubber oil plug was there when the cam bushing was installed ?
    78 atc 90/180cc Dickson Full Suspension
    76 ATC90/180cc Nicholson
    77 atc 90 Dickson Full Suspension
    84 KLT 110/123cc Powroll Racer from 80s
    87 atc 125m stock
    84 atc 200x Curtis Sparks
    84 atc 200x Powroll My race bike from 80's
    83 atc70/108cc Powroll blue Xmas Special
    81 atc185s HP-ATC full suspension

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  4. #4
    Join Date
    Apr 2025
    Location
    Corpus christi, Tx.
    --
    6
    The oil plug is there for sure. The timing chain chewed into the case a little before I rebuilt it because it was so loose. It the top wasn't getting oil, I should be hearing it right? Its as perfect as it gets. Sounds like a sewing machine that has a pair. Haha. No ticking or anything.

  5. #5
    Join Date
    Jul 2009
    Location
    South Florida
    --
    6,778
    A loose timing chain would definitely cause the metal , hopefully you replaced that and both guides ?
    Proper cam chain tension / adjustment is important .
    Easy way to see if you’re getting oil to the topend is to remove the front valve cap and start it for a second, should see oil squirting out .
    78 atc 90/180cc Dickson Full Suspension
    76 ATC90/180cc Nicholson
    77 atc 90 Dickson Full Suspension
    84 KLT 110/123cc Powroll Racer from 80s
    87 atc 125m stock
    84 atc 200x Curtis Sparks
    84 atc 200x Powroll My race bike from 80's
    83 atc70/108cc Powroll blue Xmas Special
    81 atc185s HP-ATC full suspension

    Performance Shop is Open PM me for Service

    My Feedback http://www.3wheelerworld.com/showthr...ck+shortline10

  6. #6
    Join Date
    Apr 2025
    Location
    Corpus christi, Tx.
    --
    6
    I replaced everything for the chain. Both gears, DID chain, both tensioner, the spring on the bottom and it's adjusted right. I checked for.oil up top but not with it running. The pocket was full and the rockers were wet. Ill do it running. The oil pump was about the only thing I didn't replace but it looked great.

  7. #7
    Join Date
    Apr 2025
    Location
    Corpus christi, Tx.
    --
    6
    I just pulled the cap on the top of the head. It has plenty of oil pressure. It just made a mess within 2 seconds of starting it. It must be the clutch. The basket is also original and the fingers were a little wavy. My wife said I had to wait till May for that part. I wish wiseco still made one for this. I am able to get a new honda one for about 375. My frictions and steels are new honda.
    Last edited by M14dan; 04-13-2025 at 04:23 PM.

  8. #8
    Join Date
    Jul 2009
    Location
    South Florida
    --
    6,778
    If it’s clutch noise then it should go away when the clutch is pulled in .
    The clutch basket can be filed one time to get rid of the groves as long as it’s not excessive .
    The top ends are notoriously loude when the bushings / head are worn on the camshaft .
    A touchup on the valve adjustment might be needed to get it as quiet as possible , adjust them on the tight side to counter act for a worn topend .
    Also a good straight 50w non synthetic wet clutch oil helps
    78 atc 90/180cc Dickson Full Suspension
    76 ATC90/180cc Nicholson
    77 atc 90 Dickson Full Suspension
    84 KLT 110/123cc Powroll Racer from 80s
    87 atc 125m stock
    84 atc 200x Curtis Sparks
    84 atc 200x Powroll My race bike from 80's
    83 atc70/108cc Powroll blue Xmas Special
    81 atc185s HP-ATC full suspension

    Performance Shop is Open PM me for Service

    My Feedback http://www.3wheelerworld.com/showthr...ck+shortline10

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