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Old 03-14-2015, 10:16 AM   #1
GR0NK OP
Got some screws loose!
 
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Location: In the Valley of Bomb Runs...
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Honda BigFat...or something

1983 Honda Big Red 200E, well, what's left of one anyway. Price? Free.99
The motor is all there but it was left outside without a spark plug.





Despite it not having ANY wheels on it, I think it has accommodations for one too many wheels...



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GR0NK screwed with this post 03-16-2015 at 12:28 PM
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Old 03-14-2015, 10:40 AM   #2
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Right. Now let's get to it.

No use in going any further if the motor is not serviceable so out it comes for disassembly.



It won't turn over so I'm thinking the cylinder is in pretty rough shape. On the way there I see the cam journal looks a little scuffed up on the chain side. Maybe it was oil starved for a bit.





The other side rides in a bushing and is good. I'm not really concerned and I think I'll just run it. It's not a race engine or anything.


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GR0NK screwed with this post 03-16-2015 at 12:28 PM
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Old 03-14-2015, 10:47 AM   #3
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This looks yummy...






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GR0NK screwed with this post 03-16-2015 at 12:27 PM
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Old 03-14-2015, 10:59 AM   #4
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I was able to "massage" the cylinder off. I think it will buff out.



A quick look at the piston gave me a theory on how this particular machine was left to rot for so long. It's not quite evident in the next photo but the top ring is stuck. The second compression ring is actually loose but he oil scrapper is tight as well. I've seen this before on motors that ingest cold water through the intake. The top ring instantly seizes in the ring groove. Not uncommon for a three-wheeler to ingest water in these parts.



After some cleaning up I think the cylinder will be ok. The piston doesn't look too bad after removing the rings and a bit of cleaning up but my experience tells me to get a new top-end kit anyway. I don't trust pistons that have had a ring seize in them before.


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Old 03-14-2015, 11:09 AM   #5
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A quick rinse in the parts washer and a few minutes with the hone...





There's a line in there that looks like a crack in the cylinder wall. I just noticed it now so I'll take a better look at it. I think it's merely a scratch and that the lighting is making it look worse than it really is.

I know the top of the cylinder still looks rough but it's just staining. The actual surface is very smooth. I can get a piston in 0.5mm oversize so I may take the hone to it some more until it's right for one.


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Old 03-14-2015, 11:22 AM   #6
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Surprisingly the valves were not leaking but there's no way I was going to leave them as is.

I couldn't find my valve spring compressor so I improvised.



It's just an old socket and I use a 1/4" drive extension (with a 3/8" adapter) to chuck it in my drill press. Works pretty good but you need a small sandbag or something similar to prop the head at the correct angle and to support the valve from underneath.

Pretty crusty but I can clean that up.





A bit of elbow grease and some lapping compound...





And we're good.





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Old 03-14-2015, 11:48 AM   #7
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Next I'm going to tackle the ATC frame and remove the rear axle. I need to figure out what direction I'm going in as far as rear suspension. I've seen guys use a monoshock dirtbike back half and weld it to the ATC frame and then widen the swingarm to accommodate the larger rear tire. I've also seen the use of box tubing to fabricate a swingarm and use twin shocks. I can go either way.

The monoshock sounds like a great idea but it limits how much room is left under the seat and the bike ends up being a bit long. Because of this extra length the rear suspension ends up being pretty soft and rides low in the travel. I'm basically building this to be able to bushwack my way through the forest and that means over logs and rocks so I would like to have as much ground clearance as possible. I don't want to spend money on a stiffer spring either as this is a no-budget build.

Here is a monoshock setup. Notice how even unloaded the bike rides pretty low.



A twin shock setup with a homemade swingarm. Not really fond of the design and I question the strength. Also the rear axle pillow block holders look like they would catch on everything.




Here's more what I'm after:






Or another...







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Old 03-14-2015, 12:35 PM   #8
larryboy
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The best part is that little range lever.

Looks like fun!!
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Old 03-14-2015, 03:51 PM   #9
NorthernTraveler
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Valves

New valves are really cheap - less than $20 from Riders Need Store on eBay.

Shindy 07-004

I think either Western Power Sports or Rocky Mountain ATV has them also in a house brand.

Just sayin!


Also, Viton valve guides seals are a real good idea as these motors run HOT!
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Old 03-14-2015, 04:50 PM   #10
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Quote:
Originally Posted by larryboy View Post
The best part is that little range lever.

Looks like fun!!
Anything with a dual range transmission is better.


Quote:
Originally Posted by NorthernTraveler View Post
New valves are really cheap - less than $20 from Riders Need Store on eBay.

Shindy 07-004

I think either Western Power Sports or Rocky Mountain ATV has them also in a house brand.

Just sayin!


Also, Viton valve guides seals are a real good idea as these motors run HOT!
Thanks for the tip.
I'm going to just get it operational to prove the concept first. If it turns out to be as much fun as I'm hoping it will be then I'll give the motor some fresh parts to make sure it runs tip top.



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Old 03-14-2015, 06:57 PM   #11
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The carb is something else. I couldn't bear to take pictures.
Actually I was so shocked when I took the bowl off that I completely forgot about taking pictures. The float needle was actually stuck I've got the parts soaking in gas/diesel/carb cleaner. Hopefully that will soften up the crud.



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Old 03-14-2015, 09:23 PM   #12
cptmoney
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Well done, GRONK. Been quite informative watching your work. Looking good! Anxious to hear how it all unfolds...
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Old 03-15-2015, 09:41 PM   #13
Jimmy the Heater
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I've come up with a lot of crazy ideas in my head but that is wilder that any of them! I approve!
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Old 03-16-2015, 06:22 AM   #14
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Quote:
Originally Posted by cptmoney View Post
Well done, GRONK. Been quite informative watching your work. Looking good! Anxious to hear how it all unfolds...
Quote:
Originally Posted by Jimmy the Heater View Post
I've come up with a lot of crazy ideas in my head but that is wilder that any of them! I approve!
Haha. Thanks guys. I have some even wilder stuff bouncing around in the back of my head. 1976 Honda Z50 sidehack using a 125cc Chinese clone motor... I have this "special" buddy who will ride in the hack so we're calling it "The Looney Bin"

Anyway, I found a cheap Honda 200X while going through the classifieds. Long travel front end with disc brakes would be nice. It has a 1978 Suzuki TS185 motor in it...supposedly running but not actually bolted in. I'm sure that will foster another cockamamy death machine plan.

Here's a pic of it. Looks like I get tires and seat out of her too.



It's a few hours away, ok several hours so I''ll see if my buddy is up for a road trip.


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GR0NK screwed with this post 03-16-2015 at 12:24 PM
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Old 03-16-2015, 12:24 PM   #15
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Parts is parts!

Late 70s CR250. I'm probably going to take some flak from the Vintage racing guys but I think this would be a good donor for the rear end.



This thing was in my donor pile (free.99 is always the right price ) so I brought it into the garage to thaw it out. I had originally thought of getting it running again but the bottom end is rusted solid so I don't want to go down that expensive route.



Suspension is twin shock so it frees up the room under the seat for the airbox and battery and the swingarm is steel so I can chop it down the middle and widen it to fit an ATV wheel/tire.



Oh and that tank is aluminum. I wonder how that would look stripped of paint and polished up?



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