did not work the way a manual said it would, help please.

[gladiator mice]

to sum up where i am now in my process of replacing my rings and piston, i took the motor and trans out of my 83 big red 200e. using a shop manual for that specific year and model it was going smoothly. knowing the motor is two pieces (three if you count the valve cover) i removed the timing gear and tension bolt on the side of the motor, followed by the long bolt going down through the motor to the crank. i then pulled the motor upwards listening and feeling for anything that out of place. i heard the piston slide out and i pulled the motor off the studs. what i had then realized was the motor should have come apart in two pieces. im guessing this happened because the motor is old and has never been apart and has been torqued properly. i have been hitting it with a rubber mallet constantly from all sides hoping to break it free. its not coming apart. in the back of my mind i want to use a lead so i dont damage the motor but at the same time im not sure if thats a good idea yet. reason i want the motor apart is so i can hone the inside before putting the new piston and rings in. a friend of mine at work said to put the motor in a bucket of solvent and let it sit hoping the liquid will seep into the cracks freeing it up. can anyone else recommend other ways of breaking apart the two piece motor?

sorry for the long reading, but info on what has been done could help others.

[1984 honda 200s]

Ok so the cylinder head and cylinder itself is stuck together? - keep doing what your doing, it will come appart, or pry inbetween the 2 halfs all the way around it carefully.

[gladiator mice]

yea i bet one of the three studs are seized. i could get either a flat chisel or screwdriver and tap it from all sides to break the two pieces loose. or just keep wailing on it with a leather or rubber mallet.

[AutoXer]

thats what i do I carefully pry them apart with a big chisel. Just stay as close as you can to the edge of the cylnder (stay away from the outer edge of the fins)

[rdlsz24]

Keep working at it, it should come apart. I like to use a rubber mallet. If you can find a spot on the bottom of the head to give it an upwards hit it will help.

Screwdriver can be used to carefully pry as long as you stay away from mating surfaces.

Rob

[atc300r]

The 200x and 185s have a short bolt that goes down threw the head into the cylinder.Its on the left side It has either a 8 or 10 mill head.

[gladiator mice]

The 200x and 185s have a short bolt that goes down threw the head into the cylinder.Its on the left side It has either a 8 or 10 mill head.

good to know if i had a 200x or 185. i checked out a exploded view of a 83 200e motor on bike bandit. the only thing between the cylinder head and cylinder body are guide studs. there are no more bolts or set screws holding these two together. on the big red there is a long bolt that runs on the outside under the CDI and next to the timing chain that bolts into the trans, the other 4 long studs just clamp everything down to the trans. its a matter of vibration and impact that will free the two apart now.

[atc300r]

The one I was talking about you have out.The reason I mentioned the 200x/185s is they are similar to the 200e.You have the head and cylinder off.It could be the head gasket.If this is the first time coming apart .The gaskets can realy hold on .Good Luck.Can you post some pics.

[gladiator mice]

i can post some later tonight. by the time i get to working on the motor, its almost 8pm. if you dont see them tonight, they will be up saturday sometime.

[Nick762]

I used a piece of wood and a to get more oomph outta it. Took it off good, wouldn't come off before that.

[gladiator mice]

finally got it apart, i just kept hitting it with the leather mallet and it seperated a little and a few more hits and i was able to pull them apart by hand. went to go see if the new piston would fit and it was bigger then the cylinder. so i started to check all the numbers on the box and try to match them up along with the gaskets. the gaskets didnt even look similar to mine and the main box was correct numbers but all the parts and piston were incorrect. found in small print the words "polaris atv 400" written on the gasket bag and on the piston box. NOT impressed one bit with dennis kirk right now. after multiple times calling the customer service number and being on hold i ended up talking with a nice lady who helped me get the right numbers and parts needed for my rebuild. so i wait till monday to ship my incorrect parts back to DK and another 7-10 business days before i get my correct kit. whole weekend rebuilding shot down thanks to some greenhorn working the parts orders.

this is how it came off


after the mallet hitting result


no wear on the piston, minor carbon build up on the piston head but good oil coverage


she might be old and dirty but its a classic