Engine ID help!

[Christopher Middleton]

I was given a "Go-Kart" its an old Carter brothers dlx150 but the engine is not the same that came with this Kart. I am trying to ID it so i can look at getting some parts for it. the pictures attached are of the motor and the only ID marks on it. I am thinking its some sort of 200cc from the 1980's does anyone have a better Idea? I am really trying to get a rebuild kit for the carburetor. on the carburetor is  Keihin 63 AA YKT

[Frank Angerano]

Wow cool mod to a go kart.

It looks like an old Honda atc 200 engine. Maybe 82-85 on the year. 

[Christopher Middleton]

Thank you so much this helped out greatly! now if i can find the other stuff I need to finish it off. I miss the days where you could walk into a auto store or tractor store and say I need something like this. and they would go match it up to something that may work. Now every time I go into a store like this they say I need a specific make and model in order to help you. Sad Times!

 

 

Edited June 4, 2019 by Christopher Middleton

[Frank Angerano]

I know the feeling. But keep in mind that the Honda dealers can help you out with old parts when in need but eBay has most of the stuff your looking for.  Also my response was just a guess.  I could be wrong but I bet I’m in the ball park. 

What’s on the list of things to do ? 

[Christopher Middleton]

carb is almost done. just realized that the idle jet is plugged. (dang that hole is to small to get anything through it.) The main problem I am having is coming up with a shifter for it. The people that had it before me rigged in a lever type shifter that connected to the engine with tie rod type ends. it worked as long as you are the only one in the Kart. as soon as you get 2 adults in it you can shift up in gear but not down. so i was trying to see if something like this https://www.jegs.com/i/B-M/130/80831/10002/-1

but no one will go look in their inventory to see if they have something like it I could look at. Don't want to spend 70 bucks on a thing that wont work.

last thing is I am missing the gear between the starter and (insert or gear name inside the case here) the started is frozen want to get it out to repair or replace it but i cant get the dang thing out. it looks like you have to crack the case to pull it out. this is last because it has the good old trusty pull start lol. it does fire up on the first pull still if i can get this carb worked out.

[Frank Angerano]

Take a piece of a bicycle brake cable and separate the strands and use one of the strands. It works great.  Or go on amazon and they have a small kit that has all sorts of small cleaning tips for that work.  Just look up a carburetor cleaning tool.  

As far as the shifter goes I would have a welder make up some linkage and do some custom work.   BUT YOU HAVE TO DISCONNECT ALL ELECTRICAL ITEMS ON THE ENGINE BEFORE YOU WELD ON THE FRAME! you will do damage to the stator coil and rectifier.  

The starter will come out it’s going to take some finesse.   Look on YouTube and search starter removal on an atc 200 Honda and see what comes up.   

[Christopher Middleton]

Thanks for the carb trick. Finally worked it through. Here is a couple of pics of the starter my finger points to the parts in the way

[Frank Angerano]

Your welcome. That part your pointing to is your cam chain tensioner. If it’s in the way of the statue then you  can remove it and put it back. However.... once it’s out do not rotate the engine because that tensioner keeps pressure (tension) on your timing chain.  Rotating the engine while the tensioner is out can allow the chain to jump and throw the timing off. So pull the tensioner out do what you have to do and put it back in. 

[Christopher Middleton]

Well i think this starter blew up lol

[Frank Angerano]

Yep looks that way.  Got it out ok ? 

[Christopher Middleton]

Yes thanks for the tip. I didnt know what that was that was in the way so wasnt going to play with it. Now trying to find a replacement is not being easy. 

[Frank Angerano]

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F163598132368

 

maybe it’s the one?

[Christopher Middleton]

The tooth looks like it but the other end looks way different. It says its a SM-13 12v while the one i pulled says its a M-8 12v

Sorry SM-8

[Frank Angerano]

Keyword the exact one you have on eBay. See what comes up 

[Christopher Middleton]

So today has been a good day. I found a really cool guy at the local honda dealer. Yea i know right,  WHAT?? So he looked up all the 200 atc's 1982-86 that had starters looked up the part number and then hr knew someone that remakes them. The picture looked different to me but he said its just a generic picture and that he would guarantee its the right one or he'll refund the money to me. With that info i was able to find a 1984 honda atc 200es wiring diagram and it matches. So starter ordered and reworking harnes now to clean up the engine area up. I hate dangling wires. Wish me luck! 

Oh byw what is this for? Forgot to ask

[Christopher Middleton]

Any thoughts on the above picture? That hise come out of the head on top. It is short and not attached to anything else. Not sure what to do with it.

[Frank Angerano]

Should be just a breather hose for the head assembly. Some of them ran to the air box but I don’t know if you still have that in place due to the type of set up on that kart.  

[Christopher Middleton]

So I am missing the reducing gear as well for the starter. I picked one up for 10 bucks on a chance and its a 53tooth/18tooth which is to big. Same with the pin it rides on.  I am thinking its a 43tooth/? any ideas?

 

[Christopher Middleton]

So AFTER MANY HOURS I found that everyone has been wrong about the engine. it is definitely a 1986 trx200 sx. by finding a list of serial number to engine ID now to try and find a starter that is not 245 dollars.

https://ricksmotorsportelectrics.com/Rebuilt-Honda-Starter-Motor-60_122

 

[Frank Angerano]

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F133062817000

[Christopher Middleton]

holy cow not sure how you found that that cheap I have been searching all day on eBay.  Thanks should be here by the 21-25th fingers crossed. now to go have the honda dealer return the other one. it was for the 250cc not the 200

[Frank Angerano]

Hope it works out brother.  

Good luck. 

[Christopher Middleton]

does anyone know a clear Wiring diagram for a 1986 Honda TRX200SX can be found without having to buy a membership somewhere? I can find the 1984's everywhere but not the 86. I have a Red wire that comes from the regulator(rectifier) to the key ignition but it splits off someone has cut this wire. I suspect that it runs to the battery with a 15amp inline fuse but want to be sure.

[Frank Angerano]

You are 100% correct. That red wire comes from the regulator and splits to the ignition and the battery. And yes it’s a 15 amp fuse located at the battery.  

[Frank Angerano]

Try these solder seal connectors. I use them all the time and like them.  All you need is a heat source. Heat gun, small propane torch or a hair dryer on hot setting and up close.   

 

120PCS Solder Seal Wire Connectors - Ndgenous Solder Seal - Electrical Wire Soldering - Waterproof Insulated Butt Splice Connectors for Electrical, Automotive, Marine, Boat, Truck & Trailer Wiring https://www.amazon.com/dp/B07M6ZWHH6/ref=cm_sw_r_cp_api_i_TnAcDb0YAYQMS

[Christopher Middleton]

I only need one though lol. I'll just do my solder, crimp and heat shrink. I wanted to let you know though that I got that starter in and its like brand new don't even need to buy a brush kit for it. You helped me out a ton on that find!

 

[Christopher Middleton]

also not sure if you guys can add this to a pin for honda engine id questions, but I found this huge database on serial numbers stamped on engine to engine year and type this is how I found out the exact year and engine I have.

https://4-stroke.net/honda-vin-to-year-code-list.html?resetfilters=0&clearordering=0&clearfilters=0&group_by=vin___honda_model

[Christopher Middleton]

also that 15amp fuse is it a slow blow fuse or should a regular 15amp car fuse work?

[Frank Angerano]

A regular 15 amp fuse will be fine.  I’m sure that data base on the engine id will come in handy   

Im glad the starter worked out for you it was just a lucky find.   

Good luck.  

[Christopher Middleton]

If its not one thing its another. I received the reducing gear to day and put it in. hooked up the battery to test it. It sounded really ruff. so i pulled the reducing gear back out and noticed this crack in the left stater case. Honda part# 11341-HB3-000. Has anyone ever tried to weld these up. I am a CnC programmer so cleaning things back up wont be a problem. I was thinking of getting a brass pin and stick it in then have our local welding company weld it. Only thing is I hear that castings are not weldable any thoughts before i try to disassemble. If I go this route what crap storm am I opening taking this apart?