185s / 200s / etc. Pull Start Rebuild

[utahlugers]

So, the last one is 'missing' and I am recreating it here.

I am going to post each step by step so when asking questions you can refer to the post number. :thumbsup:

The first reason to rebuild your pullstart... Its broke! :shocked:

[utahlugers]

The basic kit for your rebuild. 8mm, 10mm, Small Flat Head Screw Driver, Big Philips Screw Driver, and places to put stuff.

[utahlugers]

Begin by removing the spark plug. This should easily pull off.

[utahlugers]

Using the 10mm, unbolt the foot peg for shifting.

[utahlugers]

Using the 8mm, unbolt the 4 bolts holding on the Housing.

[utahlugers]

A small flexible holder holds this Decompression Cable, gently bend it up to release the it. It can be rebent easily.

[utahlugers]

The Decompression Cable is held on by a small retainer. Using the Philips Screw Driver, unscrew this retainer.

[utahlugers]

After unscrewing the retainer, the Decompression Cable should come down and allow you to move the wire out of the small space provided.

[utahlugers]

With the pull start off, gently lift around the edges of the yellow area holder.

[utahlugers]

As the yellow holder is removed, remove the sliding clip used to hold on the other side of the Decompression Cable.

[utahlugers]

Using the small Flat Head Screw Driver, pull off the c-clip holding on the copper peice. Then remove the copper peice. Its directional, so you may have to play with it.

[utahlugers]

Remove the Friction Plate slowly in case peices became out of place. Then remove the Friction Spring.

[utahlugers]

Remove the Setting Springs and the 3 Pawls. Then remove the Housing holding the rope. Twist the Housing counter-clockwise 1 time before removal and continue twisting during removal.

[utahlugers]

If you are replacing the recoil spring, locate a flat, secured, board. Put 2 nails next to each other in the board. Make sure they have a top to them.

[utahlugers]

This is the size of retaining wire you will need. It should fit just inside the area the recoil spring was inside the Housing.

[utahlugers]

Place the recoil spring onto the board to twist the outside counter-clockwise. The inside of the recoil spring should grab one of the nails.

[utahlugers]

After winding up several times, be sure to hold it down because it WILL shoot out if you don't hold it.

[utahlugers]

Using the wire, CAREFULLY slide it under your hand over the recoil spring. As you let go of the spring, it will rotate till it stops. This is fine. Be sure to keep the wire around the spring.

[utahlugers]

Place the newly wound recoil spring inside the Housing. Be sure to hold it down while you slowly remove the wire holder.

[utahlugers]

Feed your new rope through the hole in the rope holder and wind the rope around it till there is no more room to wind. Tape it to the inside and top for later.

[utahlugers]

Place the rope holder inside the Housing. Wind it up 4 or 5 times and then pry the tape away from the holder and out of the hole. Pull it out and tie a knot about 12 inches out giving room to feed the rope into the handle.

[utahlugers]

Place the Pawls and the Setting Springs back into their holders. The Pawls point clockwise and the bump of the Setting Springs face out.
http://www.3wheeler.org/vb/attachment.php?attachmentid=12249&stc=1&d=1190914531

[utahlugers]

Put the Friction Spring back on the post and place the Friction Plate over the Friction Spring, Pawls, and Setting Springs.
http://www.3wheeler.org/vb/attachment.php?attachmentid=12248&stc=1&d=1190914495

[utahlugers]

The copper peice goes on next and hold it together using the c-clip. You may need to use the Flat Head Screw Driver to put the c-clip on.
http://www.3wheeler.org/vb/attachment.php?attachmentid=12247&stc=1&d=1190914457

[utahlugers]

Take the spring spring with 3 coils and place it in with the bottom part to the right of the big hole.
(Into the Housing as shown)

[utahlugers]

I place the other side inside the Housing to make it easier to push in after the yellow peice is in.

[utahlugers]

The Decompression Cable goes into its hole (may need some pushing) and the ball of the Cable is placed into the slide. Make sure the slide is over the knob on the Housing and flush with the yellow peice.
http://www.3wheeler.org/vb/attachment.php?attachmentid=12246&stc=1&d=1190914416

[utahlugers]

Place the Housing back onto the ATC and bolt it down with the 8mm.
http://www.3wheeler.org/vb/attachment.php?attachmentid=12241&stc=1&d=1190914219

[utahlugers]

Bend the flexible holder back down over the Decompression Cable.
http://www.3wheeler.org/vb/attachment.php?attachmentid=12242&stc=1&d=1190914252

[utahlugers]

Place the end of the Decompression Cable back into the lever and pull it up.
http://www.3wheeler.org/vb/attachment.php?attachmentid=12244&stc=1&d=1190914332

[utahlugers]

Using the Philips Screw Driver, flip up the holder and screw it back down.
http://www.3wheeler.org/vb/attachment.php?attachmentid=12243&stc=1&d=1190914293

[utahlugers]

Use the 10mm to bolt back on the sifter pedal.
http://www.3wheeler.org/vb/attachment.php?attachmentid=12240&stc=1&d=1190914162

[utahlugers]

Replace the spark plug wire and you are set to ride!
http://www.3wheeler.org/vb/attachment.php?attachmentid=12239&stc=1&d=1190914121

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[Doc86R]

Couple of follow-up questions to original thread (now closed) on the 86 200s I'm working on
1) anyone know where to get new decomp cables? Service Honda gave me the dreaded "obsolete" when I tried to order one from them.

2) anyone have an extra spring left over from their rebuild kit? I think I got mine from DrATV.
http://i473.photobucket.com/albums/rr98/Doc86R/trikes/200s/pullstart%20rebuild/pullstarterrebuild014.jpg

3) anyone use a 2nd gasket on the cover? Looks to me like the original design of the recoil backing plate was smaller and did not cover the entire gasket. When I reassembled, I put the gasket beneath the recoil plate (painted blue in pic) as shown in Utah's excellent thread and the recoil action is smooth. Without the gasket, the plastic piece sometimes hangs up.
http://i473.photobucket.com/albums/rr98/Doc86R/trikes/200s/pullstart%20rebuild/pullstarterrebuild015.jpg
I'll probably pick up a 2nd gasket 28411-VM3-306 sometime and see if the dogs engage correctly with 2 gaskets (one on either side of the recoil plate) unless someone has already tried this unsuccessfully.

Dads - if you think these questions and replies are worthwhile can you unlock and add them to the original thread?

[ADW3]

btt

[cue420]

show how you put the yellow piece in. this is where im stuck on the spring connects to the yellow....

[86200s]

Does anyone know what the diameter of the pull rope is?.......mm or inches. There is some kick a$$ Kevlar rope available but I don't know if the diameter is small enough. Any takers on this Kevlar rope idea? After all its only 2 bucks a foot!

[86200s]

So, the last one is 'missing' and I am recreating it here.

I am going to post each step by step so when asking questions you can refer to the post number. :thumbsup:

The first reason to rebuild your pullstart... Its broke! :shocked:

Does anyone know what the diameter of the pull rope is?.......mm or inches. There is some kick a$$ Kevlar rope available but I don't know if the diameter is small enough. Any takers on this Kevlar rope idea? After all its only 2 bucks a foot!

[yamaha225]

Using the 10mm, unbolt the foot peg for shifting.

i've done this many times an you can just shift the shifter into 1st an hold it then slide the pull start right by it an shift it back to neutral then do the same to put it on

[first three wheeler]

If the recoil rpoe does not return what is the problem?.I would think the main spring but this recoil has been redone three or four times for the the last two owners buy the same shop. Maybe a new shop ?.

[yamaha225]

If the recoil rpoe does not return what is the problem?.I would think the main spring but this recoil has been redone three or four times for the the last two owners buy the same shop. Maybe a new shop ?.

do it your self just make sure the spring is wound up enough

[frankcrw]

when i hook my decompression on my starter and put on the bike it will pull out but will not retract in

[rchrugg]

Hi Frank
Thanks for the great post. I have a question about the drum sprting: Where the heck does it go? Does it go inside the in the area between the ratchet cover and the outter cup, or does it go outside of the cup. I have completed everything else, but every photo I see of this doesn't explain.
Thanks
Rich

[mustangmuncher95]

ok these photos are great! the only thing is that i cannot figure out how the spring for the yellow piece goes in.... when i put the spring in the yellow and place it all back togethor with the 8mm bolts to the housing the yellow puts pressure on the recoil and the rope will not go back in.... but if i loosen the 8mm bolts it works fine... what am i doing wrong????

[feist350x]

seeing ur pics brings back old memorys 4 me when I had my 82 ATC 200

[kodiak117]

Good step by step the only part I dont understand is when the decomp. cable is reinstalled how is the spring reattached to the yellow piece have tried many ways ,cant figure out how spring attaches to yellow piece. Any help greatlt appreciated.

[garen]

I'm missing the assembly inside the recoil that the decompression cable hooks into. The outermost assembly that screws into the recoil. Perhaps its called the decompression retainer assembly. Do you know where to buy one of these on a 1984 ATC 200s? Many Thanks.

[Grifter]

I found this really helpfull. I am rebuilding a 1982 atc 200. When I got the bike the decrompression cable had been removed. I only have a few of the parts. I will probably in the future try to make the decompression cable functional again. It looks like you got your stuff together on your 82. I am trying to find the placement of all the brake cabels. If you could take pictures of their positions it would help me out a whole bunch.:thumbsup:

[rws]

84-86 200S shop manual (http://72.52.143.80/~trikes/Manuals/ATC%20manuals/ATC200S%2084-86%20Shop%20Manual.pdf)

Section 9 in manual shows how to assemble the recoil with decompression.