85 200x kicker gears repair

[Jonpin]

Just wanted to ask if anyone has replaced the kicker gears in an 85 200x is it a real trailpro or is it not bad i do have the pdf guide but it does look a bit crazy and iv never done a lower end ,not being able to kick the bike over is horrible and makes it look like a bum bike haveing to be pulled to start and i just cant have that.

I have the gaskets already and everything just not anywhere to realy work on it at need to make a bench but need to make space for that. "So overwhelmed"

[Dirtcrasher]

It's not fun..... You have to have a real clean work space and a good light, nobody distracting you!! And of course, a few tools to get the flywheel off, the crank out and in without bending it and the 200X rotor and basket nut tool.

I won't say it's hard. But I will say it's very easy to mess it up. To some guys, splitting cases is like changing a tire. To other guys, they think they can do it but they damage allot of stuff in the process, most of which isn't even visible; It's the procedure they use!

You see, thats the issue with manuals, they done explain WHY things are done a certain way and what can happen if you do otherwise. Merely using a puller or press in the wrong way can ruin parts, without you seeing it! It would only be because you were never taught the basics which anyone who's a decent mechanic can make sense of......

Your in Florida? I'd clean that motor spotless, drain the oil when hot and find a member on the boards that seems to know his stuff and work together. It's truely the best way to learn.....

The gears themselves, unless you have new ones and someone figured out a way to back cut them them with some UNIFORMITY!! I'd make sure your all set before the operation starts. I can backcut gears with a 1/8th wheel on my grinder too! But I would think the best way would to use a mill with a rotary table to get every gear the same, or more stress is placed on gears that mesh versus ones that aren't meshing.

I'm not getting on the guys doing it by hand, I ADMIRE them and I hope it works out for all you 85 guys with kicker issues.............

[Jonpin]

Sounds horrible i have one lower end just need the spring and 2 350x engines that i need to split cases on :(

[shortline10]

Your not to far from me let me know if you need help?
I'm in Fort Lauderdale area.

[rdlsz24]

What are the symptoms of the kicker gear problem?

Rob

[Jonpin]

What are the symptoms of the kicker gear problem?

Rob

Well you try to kick it and all of a sudden you find your foot violently flying towards the ground and hurts then you try again and it moves freely but catching at the very bottom and turning the engine just a lil bit and have to try to find the sweet spot and try and hope its going to let you get a full kick out of it or its going to hurt again lol and if it gets a half kick you hear the gears catch up to eachother and grinding while the engine turns over not sure if thats a great description but its the best i can come up with at this time just got off work and its 3:46 am and tired. all tips and help are much appreciated.

[shortline10]

Well you try to kick it and all of a sudden you find your foot violently flying towards the ground and hurts then you try again and it moves freely but catching at the very bottom and turning the engine just a lil bit and have to try to find the sweet spot and try and hope its going to let you get a full kick out of it or its going to hurt again lol and if it gets a half kick you hear the gears catch up to eachother and grinding while the engine turns over not sure if thats a great description but its the best i can come up with at this time just got off work and its 3:46 am and tired. all tips and help are much appreciated.


Sounds like a weak ratchet spring and worn ratchet teeth to me . If it grabs sometimes their is hope to rebuild it .:)

[Jonpin]

Sounds like a weak ratchet spring and worn ratchet teeth to me . If it grabs sometimes their is hope to rebuild it .:)

Well thats great to hear i always like some hope :) i have 2 other lower ends one with good kicker function but makes noise in 4th gear "that what it says on the tape on it" and one that says needs kicker gears or spring i know the springs bad the kicker dont return came with the the bike when i got it with a rebuilt head new valves was going to try to put those together to make a good one and see how that goes and if its not to bad fix the engine thats in the bike now and have a spare.

[rdlsz24]

Well you try to kick it and all of a sudden you find your foot violently flying towards the ground and hurts then you try again and it moves freely but catching at the very bottom and turning the engine just a lil bit and have to try to find the sweet spot and try and hope its going to let you get a full kick out of it or its going to hurt again lol and if it gets a half kick you hear the gears catch up to eachother and grinding while the engine turns over not sure if thats a great description but its the best i can come up with at this time just got off work and its 3:46 am and tired. all tips and help are much appreciated.

Mine is kinda like that but only since I got it bored 20 over and put in a Wiseco. When it had a junk piston it kicked over like butter because of the low compression. Can great compression magnify this problem?

Rob

[Jonpin]

Mine is kinda like that but only since I got it bored 20 over and put in a Wiseco. When it had a junk piston it kicked over like butter because of the low compression. Can great compression magnify this problem?

Rob

I could see that with what shortline said about a weak rathet spring more compression putting more stress on the ratchet like a worn out socket wrench. i wonder if you can just stretch the ratchet sping a lil bit to fix the problem but the teeth are probly already worn.

[greenhuman]

It's not fun..... You have to have a real clean work space and a good light, nobody distracting you!! And of course, a few tools to get the flywheel off, the crank out and in without bending it and the 200X rotor and basket nut tool.

I won't say it's hard. But I will say it's very easy to mess it up. To some guys, splitting cases is like changing a tire. To other guys, they think they can do it but they damage allot of stuff in the process, most of which isn't even visible; It's the procedure they use!

You see, thats the issue with manuals, they done explain WHY things are done a certain way and what can happen if you do otherwise. Merely using a puller or press in the wrong way can ruin parts, without you seeing it! It would only be because you were never taught the basics which anyone who's a decent mechanic can make sense of......

Your in Florida? I'd clean that motor spotless, drain the oil when hot and find a member on the boards that seems to know his stuff and work together. It's truely the best way to learn.....

The gears themselves, unless you have new ones and someone figured out a way to back cut them them with some UNIFORMITY!! I'd make sure your all set before the operation starts. I can backcut gears with a 1/8th wheel on my grinder too! But I would think the best way would to use a mill with a rotary table to get every gear the same, or more stress is placed on gears that mesh versus ones that aren't meshing.

I'm not getting on the guys doing it by hand, I ADMIRE them and I hope it works out for all you 85 guys with kicker issues.............
Thats the thing. This mod works so well it does not have to be perfect though machine grinding would look nicer.
I have done tons of kicker gears with a small angle grinder and there has never been a slipping issue ever again.

[Bryan Raffa]

:d :d :d :d and get the SHIM washers from DAD's

[seadoo650]

I'm getting ready to do this on an 85 200X. I'll post pics of the steps along the way along with the tools and techniques. Kinda like one of Mosh's how to threads. I might start today.

[Jonpin]

I'm getting ready to do this on an 85 200X. I'll post pics of the steps along the way along with the tools and techniques. Kinda like one of Mosh's how to threads. I might start today.

That would be very awsome

[Jonpin]

:beer
:d :d :d :d and get the SHIM washers from DAD's
Thanks for the pic but man it looks like 2 of those parts are made from some crappy pot metal no wonder they go bad

[Texas 200x]

When I did mine I got new gears but they don't sell the spring anymore. I stretched my spring out and heated it with a torch just for a second or two. It has worked good since. I wish I would have known about the back cutting of gears. I would go with the back cutting if you can. If you take it apart use the illustrated parts lists to make sure everything is in there and in order. I've pulled motors apart and found people before me forget to put stuff in and even the right direction. Take pictures with a digital so you can look when your reassemble. It can be overwhelming but if your a mechanical person (you know if you are), its not as bad as you think. Take your time do it right don't skimp or half-ass. Read the manual sections in complete a time or two before you start. Good luck!

[Erics350x]

I think i reda some where that you can add a shim or two to the spring and solve the intermediate slip

[TrailerRider]

Noob question alert!

:wondering Is this slip related to all 83/85 x's?

[seadoo650]

Noob question alert!

:wondering Is this slip related to all 83/85 x's?

Unfortunatley yes. It was appearantly a design flaw from the factory. Honda issued rebuild kits for them but I think those are long gone.

[rdlsz24]

I wish I could compare mine to one that has been fixed to see if I have it. I don't really notice much out of the ordinary, but this is also the only toy with a kicker I have ever had.

Rob

[MonroeMike]

Noob question alert!

:wondering Is this slip related to all 83/85 x's?


http://www.3wheelerworldforums.com/showthread.php?t=45445