Hello All,

I am currently trying to rebuild my 85 200x but have run into a couple of problems. First being that I dont have a manuel.

Once I get the "cone" and cluch basket out of the way is there anything that will jump out and surprise me??

Next problem, I currently have the engine out of the frame with the top end completely removed. When I pulled the jug I found that the bottom of the piston had broke out and the wrist pin was only held in by one side and at the bottom of the stroke, the wrist pin smacked the sleeve and broke it. So obviously that means new piston, pin and clips but what about the jug. Is that a press in sleeve that I can get replaced cheaply or do I buy a new one?

Connecting rod has a lot of slack left to right, maybe 1/2" either direction. I am guessing that this is what broke out the piston and lead to the rest of the problems. I know that I cant tell if the crank is good or not until I get the cases split and the rod off, or is it a press on rod with a sealed bearing?? That would be cool as it would save the crank. I think.

Anyway comments and ridicule are all welcome,

 

1.When you get the clutch basket off, there is only a Washer behind it, nothing more (BUT keep track of it...VERY IMPORTANT!!!!)

2. If the sleeve is broke, call your local shops and see what it would run to get a new sleeve installed ( BUT it is going to be cheaper to buy a used one off e-bay Mostlikley.

3. The crank is pressed together around the rod. See if there is any up-down movement, and the side to side is .05mm to .30mm max, just slide a feeler gauge between the side of the rod and crank.

 

OH yea........Welcome to the forum! [img]i/expressions/face-icon-small-happy.gif[/img][img]i/expressions/face-icon-small-happy.gif[/img]

 

Thanks for the quick feed back.

Dont have any up & down motion. Im not really able to check the crank to rod clearance. There are what I am assuming (Yes I know about assume) to be thrust washers on either side. Correct?? Anyway they are taking up the "gap" there. I am just going to have to pull everything out and start fresh.

What is a decent $ for a used jug

 

You should be able to get a good used jug for under $100......