Christopher Middleton

Thanks this is my work toys!

Well ehat do you think. Test will be tonight.

Lots of research lol, and many years of rebuilding cars with my father and grandpa.

I would love a quad but there is no where near me that have trails I can ride. I was given this project for free. I love tinkering on little things like this. I am hoping to flip it to help pay to take my kid on a vacation.

Just so you know about what i mean about my machine.

I hear you about that. All the ones i come across all have cracks abd pretty beat up for the price. I think im going to try and put it up on my machine tomorrow and try to map this out. I should be able to get it close by a couple thousands. (0.001) of where it needs to be. If i have enough pull at my work I might be able to get them to 3d scan it but not sure.

I have access to a an aerospace welding company that owes me some favors. They even have laser welding capabilities. Here is a picture of what the inside looks like. You can see its really blown out. Do you guys think if i have that completely welded in and machined it back to where it should be. That it would hold, or should I try looking for a replacement. Haven't had luck on a decent looking one.

Ask the mechanic how much it would be if you supplied the parts. usually you can get that price cut in half if not more if they don't have to go through the dealer connects that most of them do.

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?

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

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

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!

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.

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

Anyone have one or know where to get a replacement or the body of one? I found one place but they want $245.00 for it and at that price ill just keep pull starting it. I live in Michigan. i have all the old parts but the magnets blew up in this one. I think previous owners tried to free it up with a sledge lol

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

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?

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.

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

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

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.

Well i think this starter blew up lol

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

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.

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!