possible 85 200x transmission problem??????

[hoosierlogger]

I think I might have pooched something up in my transmission during the engine rebuild. Here is whats happening. I noticed while tightening the drive sprocket bolts that the shaft turned in a jerky manner. It didnt hold solid like it was in gear, but didnt turn easy like it is in neutral either. Kind of in between, and you cant turn it by hand. I assumed it had gotten knocked in between gears during assembly. So I put the shifter lever on to try to get it in neutral. The SOB wont change gears. The lever moves up and down, but not enough to initiate a gear change.

Does this sound like friction due to no engine oil yet, or possibly not enough leverage on the shifter arm (it is not bolted to anything solid yet). This is really going to piss me off if I have to open it up again. I payed real close attention to the manual during assembly, and it all turned easily by hand when I put the case halves together. Rotating the shift drum by hand let it go into different gears before case halves went together.

[Howdy]

It could be a washer slipped out of position and knocked the gears out of sync. It could be many other things as well. You might have to split the motor again and double check everything is in place with a blow out of the tranny in hand.

[hoosierlogger]

whats the odds of it just needing to be rocked to get it to shift? Sometimes my 4 wheeler does that. You have to rock the machine back and forth to get it to drop into gear it usually happens if you downshift too many gears while sitting still. Essentially this kind of sounds like the same thing. At least I hope thats what it is.

[1984 honda 200s]

^ my wheeler does this also, even up shifting with the bike off you gotta rocker back and forth, id give that a try, it will probably click right into gear

[hoosierlogger]

^ my wheeler does this also, even up shifting with the bike off you gotta rocker back and forth, id give that a try, it will probably click right into gear

God I hope so. Time to work on it is getting harder and harder to find every day.

[hoosierlogger]

I pulled the motor out and tore it apart again today. I found the problem. When I put it together I put the little thrust washer that was supposed to go on the kick starter on the shift drum :crazy: . Thats why it turned on the bench, but not after the motor was bolted together tight.

I feel like a huge dumb ass. At least I didnt have to pay a shop to fix it. Gasket set is supposed to be in on Thursday.

[Dirtcrasher]

Thats why I always use the connecting rod and spin my motors to run through all the gears before the top end goes on.

Good deal, cheap fix :beer

[hoosierlogger]

Thats why I always use the connecting rod and spin my motors to run through all the gears before the top end goes on.

Good deal, cheap fix :beer
I spun the shaft but not after I tightened down the cases. You can bet your life Ill do it this time I put it together.