Well why I wait to get my jug, head and cam back. I got a new EBC clutch. And started to read through the manual about how to accomplish this. It states in there that a couple of special tools are required to remove both the centrifugal clutch and the clutch basket. Are these really necessary? All there for as far as I can see is to keep it from spinning while removing the retaining nut. Will an impact do the job just fine? Or should i find these tools to use?

 

I've done this job on several different trx200sxs...
You don't need any special tools to do this job.
An Impact works fine as long as you are careful,
as one of the clutches is a Left Hand Thread.
Make sure you stake the nuts on when you put it back together,
and use a torque wrench for proper tightening.
TRX 200 sx are Great little quads....they run forever.

 

Thanks, thats good to hear. Didn't want to wreck anything. And yes these are great old quads. This was my first four wheeler. Haven't been riding much the last four years. So now that its time to get back in. I figured its cheaper to fix this up and ride it for a year or two. So its getting in upgrade in power, brakes and suspension. Should be one peppy little honda once I'm done.

Second question. I'm rebuilding the top end of the motor including cam regrind from Web Cams. What break in procedures should I fallow?

I have built many ford and chev V8's is the break in simular? Set the idle high and let it go for a half an hour? Or should I just get on it and ride the **** out of it for an hour then change fluids?

 

If you need shop manual help just PM your email address and I will email you the clutch section from the 1986-88 TRX200SX PDF shop manual ...

 

I do have a manual. Just didn't want to have to go to honda to buy there SPECIAL tools. To get the job done and who knows how much they would cost. As far as engine break in I'd rather hear peoples opinions. Sometimes theres better ways of doing things than whats in the manual.

 

So you're a car guy too...Good on ya!
Me too...mainly stock cars here.
Yeah...the breakin is pretty similar,
you know, no prolonged idling, vary your rpms,
take it easy for awhile, and change your oil really soon
after you put her back together.
The same drill as for any other engine you've just rebuilt.
Lots of different opinions on length of breakin,
myself I usually ride a rebuilt quad easy the first 3 times,
and gradually work up to full speed.
I usually change the oil after the second ride.
Wash your jug out really good
with soap and water
to get any nasty grit off, and wipe her down with oil and go for it.
I've yet to have a bad experience on a rebuild.
That's wild...one of my trx200sx's is the first quad
I ever bought new,
and it still runs great. Good Luck on your project.[img]i/expressions/beer.gif[/img]

 

Thanks, with the mid range cam, springs, head rebuild, and 1mm over piston. It should get up and go pretty good.

New question. I picked up a rear shock off a 99' 250x recon to try out on the rear of my 200sx. I found measurements for both and it looked like it might work. So for $25 I picked it up. And it is a perfict match. Now I have heard that the rear shocks on 250ex's are adjustable. Did they make 250ex's in 99' or is it off a recon? I believe they made recons in 99'. If not what is it off of?