Oil rotor cleaning: 1983-85 200X

[Glenn]

Parts needed:
Engine Oil
Metric sockets
Rubber mallet
Putty knife
Philips head screw driver
Impact driver (you may need this, you may not)
Left case cover gasket- Honda Part # 11393-KT0-710
Kick starter cover gasket- Honda Part# 11338-965-306
Oil rotor gasket- Honda part # 15459-KTO-710
A factory service manual. This guide is helpful, but you’re still going to need the manual. Don’t bother waiting for one on E-Bay….servicehonda.com sells them brand new for $32 + shipping. There’s a two-week lead, but it’s worth the wait.

This was done on a 1985 200X. You’re machine may be different, so don’t hold myself or Dan responsible.

[Glenn]

Step one: Drain your oil. There’s a spring and a metal filter behind the filter cap. Be sure to be mindful which way the filter is installed. Clean out the filter while you have it removed

[Glenn]

Step 2:
Remove the foot peg from the left side of the machine.

[Glenn]

Step 3:
Remove the kick-starter.

[Glenn]

Step 4:
Remove the brake lever and associated hardware.

[Glenn]

Step 5:
Remove the kick-starter cover bolts. Helpful hint: Lay them out in the order/location they come off.

[Glenn]

Step 6:

Remove the kick-starter cover. The cover will probably not just fall of when the bolts are removed. I tapped it “lightly” with a rubber mallet. Then, I wedged (gently!) a putty knife between the cover and the side case. Use the rubber mallet to lightly tap the putty knife if you have to.

[Glenn]

Step 7:

Now that you have the cover off, put the bolts in their proper holes. This will make putting things together a heck of a lot easier for you.

[Glenn]

Step 7.5:

Here’s shot of the kicker gears. Time to pull em' out!

[Glenn]

Step 8:

Remove the clutch cable. This is what I used to hold the clutch arm while I removed the cable. It’s just a socket and an extension.

[Glenn]

Step 9:

Remove the side case cover. This is done in a similar manner as the kick-starter cover. Remove all the bolts, lay them out the way they came off, tap the case lightly with a rubber mallet, and use the putty knife to separate the case cover from the case.

*Note—The case cover on my machine was fused on pretty good. It took a little time for me to remove it. Take your time! You don’t want to score any surfaces and then have a possible oil leak when you get things together.

(No pic for this step)

[Glenn]

Step 10:

Once you have the cover off, this is what you’re going to be looking at:
The oil rotor is on the right with the three Philips head screws and the spring.

[Glenn]

Step 11:

Mob was nice enough to pass this tip along to me. Put a penny between the gears. This will allow you to remove the rotor screws without turning the gears. If you don’t use the penny, you’ll be just turning the engine. Or, if you have it gear, you’ll be slowly moving your trike around the garage and probably swearing a lot.

[Glenn]

Remove the rotor cover. This is where you may need the impact driver. I’ve hard that these screws can be a real pain to remove. I was lucky; I was able to remove mine with just a Phillips head.

Once you have the rotor cover removed, clean out all the gunk! That’s why you took this thing apart in the first place.

Note: Make sure you remove all gasket material from the surfaces. I’m assuming I’m the first person to see these things since the trike left Japan some time in June of 1984. These gaskets will be fused to most surfaces. I gently used a razor blade to remove the old gaskets. I also cleaned down the surfaces before installing the new gasket. Again, take your time! If you rush and leave old gasket material behind, you’re bound to create an oil leak and you’ll give all the quad owners a reason to laugh at your “antique” trike that leaks oil.

[Glenn]

Reassembly:

If you put all the bolts in the covers, reassembly is literally just bolting things back up.

Note:
Make sure you align the marks on the kicker gears correctly! There’s a mark on the two gears, and the shaft itself. Line all these up and you’re good to go!

1983 Owners:
Your kicker gears are a little bit different. Don't soil your trousers if they don't look the same as the ones pictured...it's OK!



Remember to fill your machine up with oil! I put in just a bit over a quart to be safe.

Start it up, check for leaks and you should be good to go!