Tearing apart 200x motor issues

[caddymankc]

I got the motor mostly apart but im having problems getting the wrist pin out. is there any tips for removing it? and also a problem im having is what size is the bolt that threads in to pop the alternator rotor off?I dont havethe puller.
casey

[EarlyBronocGuy]

You have to get the clips out of the grooves in the piston, then the pin should slide right out. Not sure about the bolt for the alternator, but you might try either the front axle bolt or the swing arm bolt.

[beets442]

Wear safety glasses, those clips always go fly'n when I remove them:lol:

[WIkid500]

Use the front axle bolt to pull the flywheel off.

[harryredtrike]

you have a manual?or winging it?

[caddymankc]

I have the service manual, too many small parts to wing it, i have both the wrist pin clips out without losing an eye haha just cant get the pin to move more than a 1/2 inch, ill have to try the front axle bolt never would have thought of that.
casey

[Vootie]

I use a socket with a short extension on it that fits in the piston but hits the wrist pin. Give it a few taps to knock the wrist pin out.

[Sick200x]

If it doesn't move to easily while tapping it with a socket, check to make sure the circlips didn't make a burr around the grooves. If so, just file those down a bit and it should come out without too much effort. A little PB Blaster always helps too.

[WIkid500]

If need be you can always make a wrist pin press with a couple of deep sockets, some ready rod, washers and nuts.

[caddymankc]

Im gonna have try that idea with the threaded rod, i tried an extension, pb blaster, and i dont remember seeing any burrs. Also is there anyone on here that will cut my kicker gears to make it grip better?I dont have the patience to do stuff like that and ill end up taking too much off.

[WIkid500]

Im gonna have try that idea with the threaded rod, i tried an extension, pb blaster, and i dont remember seeing any burrs. Also is there anyone on here that will cut my kicker gears to make it grip better?I dont have the patience to do stuff like that and ill end up taking too much off.



It doesn't take much to file them a little bit to sharpen up the teeth. Mine slipped real bad, I filed things up so all the edges mate real nice and smooth. The other big key for me was to order the spring for the kicker from a newer xr. look at the parts schematics and buy one for the newer bike, when you get the new spring pull it apart a little to make it a bit longer this will add some extra tension. I forget which year xr I used, sorry. I have been running a 10.8-1 compression piston for about a year now and the kicker has been working great.

[Dirtcrasher]

If need be you can always make a wrist pin press with a couple of deep sockets, some ready rod, washers and nuts.

X2, this is the safest way. pistons and hammers don't go together, even light taps. Make your own little puller out of some rod and you'll be good.........

[caddymankc]

Piston is trash anyway, whoever rebuilt it before didnt put too much effort into anything, the clutch basket and the oil thing(cant think of the name right next to the oil pump) lock nuts were hand tight. the connecting rods bearings are bad it has a massive amount of play, i found 2 small washers sitting in the bottom of the case, head was missing 2 dowel pins. Im gonna have the guy i know who rebuilds racing motors see what he can do to make the head flow better and have him use a press to redbuild the crankshaft.Im also getting the jug bored to the next size just in case the previous owner used a hone in a drill to bore it out. Hopefullly by the time im done i will have a very nice 200x that i dont have to worry about letting me sit. Thanks for the helpful tips for getting the motor tore down.
casey