Freeing a Stuck ATV Motor

skiroule

skiroule

Well-known member
I'm sure some of you out there have some ideas.

A few years ago I left an older Honda 200SX ATV at my daughters to use. I'm sure it hasn't been run for at least a couple of years and when I was up there recently I found out that it won't turn over with the pull rope - most likely due to corrosion in the cylinder.

I've had pretty good luck unsticking 2 stroke snowmobile engines that have been sitting but I have no experience with 4 strokes. I didn't have time to mess with it so I just sprayed some Liquid Wrench in the cylinder to hopefully slow the deterioration.

I'd prefer to not have to tear it down. Should I pull off the recoil and try cranking it backwards with a wrench first (my usual trick)? It was running like a top when I dropped it off so I think the motor is fundamentally sound.
 
skiroule

skiroule

Well-known member
Thanks,

I might be going back up there in a couple of weeks. I'll give both remedies a shot. It would be fun to get it running again. It was a blast to ride - not a mud machine but was great for touring logging roads.
 
skiroule

skiroule

Well-known member
snowbuff said:
Any luck???
Click to expand...

I was up last weekend and threw a bunch of Marvel Mystery Oil in it. I let it soak for the better part of a day and even with my substantial amount of beef sitting on it for traction, I couldn't break it loose by rocking it.

I guess the next step is to try the heavy stuff suggested by skidoolis, although the Marvel Mystery Oil soaking time between now and when I get up there again may help. I wanted to bring it home this trip but just had too much other stuff to haul. At least it's in a shed now so it's out of the weather.

I'm still sticking with the story that if I can get it unstuck, I can get it running again (sorry about the pun).
 
skiroule

skiroule

Well-known member
robmountainking said:
I have used Coke in quite a few of these and it will take care of the issue
Click to expand...

This seems like it might actually work! Many of us remember the stories about the original Coke dissolving rusty nails. I'm putting on the list of things to try.

Does it have to be regular or will diet work? :)
 
Last edited:
S

skidoolis

New member
the lower end might be rusted also.not sure how you can soak those parts,rod,crank and so fourth might have to soak whole engine in a bucket of maybe diesel or kerosene..good luck.
 
D

doo_dr

New member
just ran across another possibility

If the pull rope handle was not covering the recoil rope outlet you may have a rusted flywheel to stator. I just came across this where the recoil spring wouldn't pull the handle into a sealed position (so water couldn't get into recoil/ flywheel area) and the rain water ran off the tank and just about perfectly dripped right into the rope inlet on the recoil. Filled the area up with water and rusted it tight. You may want to pulll the recoil housing to see if you have this issue.
 
skiroule

skiroule

Well-known member
doo_dr said:
If the pull rope handle was not covering the recoil rope outlet you may have a rusted flywheel to stator.
Click to expand...

doo_dr;

I never thought about it but this also seems like a possibility. Sitting outside in the U.P. it was undoubtedly covered with snow for several winters. There would be plenty of opportunity for melting snow to seep in around the starter rope handle - not to mention rain. I was short on time again on the last trip but I almost pulled the recoil cover. Now I wish I had.

For sure I'll be able to bring it back home in September and spend some real time on it. If the lower end is rusted, it's probably off to ATV heaven. Otherwise, I can hopefully get it broken loose make it my logging road scouting transportation for this fall.
 
Last edited:
D

doo_dr

New member
rutsted flywheel

If you do find it to be in the flywheel do not try to break it free right away. blow as much junk out of the housing as you can with compressed air. reinstall the recoil and fill it up with WD40 or some type of solvent. Let it sit a few days and then remove the recoil and start cleaning again. The rust can damage the stator and flywheel if they are large pieces. Letting it soak will help loosen up the rust and make it break into smaller pieces. Hopefully small enough to allow it to break free without damage to either flywheel or stator. The motor I just did required very little repair/cleaning to be able to reuse all of the components. I may have been lucky as most all stators are built with plates of steel with copper windings and the steel is usually exposed (process to bring the stator into clearance tollerances. If rust starts forming within the plates, the stator is junk. Rust will also loosen the magnets from the flywheel housing. Water mechanics know this stituation all too well. Good luck. I'll be interested in hearing how things turn out.
 
skiroule

skiroule

Well-known member
Thanks for the info. I'm sure that the first thing I would have done is slap a wrench on it. Will let you know how it comes out.
 
A

anonomoose

New member
I have gotten "barn bikes" up and running by the following:

A) Drain the engine crankcase completely....note if any water came out.

B) Fill the crankcase TO THE TOP with number 2 diesel....as much as you can get in there...this will free up the clutches.

C) Unscrew the spark plug and fill each jug with the diesel....and refill as it goes down...let it sit for a week or more....if you have the time.

Now drain it all out and save the stuff for the next project. It lasts for years.

If this doesn't work, it is NOT corrosion. It is a mechanical lockup and you have bigger issues going on.

Once you get it drained and assuming it will loosen up by putting in highest gear you can get it in, and then rock it back and forth...sometimes I leave a gallon in there while I do this and even if I get it loose, I leave it in there for another week.

Diesel is great stuff for breaking rusted up or corroded up stuff loose.

Once it gets moving, drain the fluid out and put cheapest oil you can find in run it for a day or two and drain it out and put the good stuff in.

And never lend this thing to your daughter again.
 
D

doo_dr

New member
That long?

"Once it gets moving, drain the fluid out and put cheapest oil you can find in run it for a day or two and drain it out and put the good stuff in."


Holly Cow " Run it for a day or two"??? Wouldn't your bike be as hot as the space shuttle during re-entry? LOL.

I have met some people that would take your advice to heart and let it run that long. I called them "My student loan and retirement fund" when I was spining wrenches.
 
skiroule

skiroule

Well-known member
anonomoose said:
And never lend this thing to your daughter again.
Click to expand...

The good advice just keeps on coming... Rest assured, it won't happen. Although, in her defense she wasn't in charge of maintaining it, but that's another story.

"Run for a day or two" - I'm slow but even I would have considered it a figure of speech. Still, I guess you can't be too careful with how you say things.
 
A

anonomoose

New member
Well, geezzzz! Anyone who is stupid enought to sit there and hold the throttle for two days, deserves what may happen. Oddly, some bikes might do that without incident. Others....well, that's what keeps mechanics going, eh?

This IS a honda....and probably in R & R, somebody has already done just that.
 
skiroule

skiroule

Well-known member
doo_dr said:
x2 with a little marvel mystery oil in the cylinder and no plug in it.
Click to expand...

Talk about dredging up an old thread but wanted to thank the contributors for helping my story have a happy ending. You guys are awesome!

When I was at my daughter's place in August I put some Marvel Mystery Oil in the Honda but even after a couple of days and some rocking attempts, I couldn't get it to budge before I had to leave.

I'm back up in the U.P. tonight (trying to post this on my daughter's laptop without a "real" mouse). When I got here I went out and tried the Honda. It pulls over as smooth as could be.

I'm confident that I can get it running now. Thanks Again.
 
You must log in or register to reply here.
Top