86 200x shifter wont move with case on?

[Matrix]

I recently switched out the old tired clutch on my 200x with a new barnett dirt digger. After I put everything back together and was ready to start it and see if I did everything right I noticed I couldn't move the shift lever. I looked through my manual and everything seems to be right. With the cover off I can move the shifter night and day but once the cover is back on its as if it is frozen in place. It doesn't appear that the cover is hitting the mechanism that is attached to the shifter either but I have no idea, I'm completely lost on this one. :(

[yaegerb]

Did you ensure the the gear on the shift drum and plunger arm are working correctly?

[pipeline triker]

when I did mine this happened. Took it back off and checked and had to line something up, then it worked nice.

[Flossyb20]

If it worked fine before, and doesn't now..it's something you did...time to pull it apart.

[Matrix]

If it worked fine before, and doesn't now..it's something you did...time to pull it apart.

How insightful!

I know its something I did. I have torn it apart a few times to look and see what I am missing but I haven't a clue. Last night was the last time I tore it apart, clutch and all and check to see if something is hitting something that it shouldn't but it doesn't look like it even though something obviously is. That's why I came on here. It's been happening for about a week now and now im missing the Malvern race thanks to it.... I guess I'll keep looking.


Did you ensure the the gear on the shift drum and plunger arm are working correctly?

I'll have to look through my manual and see what those are first. I have never had a crankcase open because I knew I would screw something up.

[yaegerb]

So when you try to shift is it stuck in one position(wont move at all) or when you shift its not grabbing gears?

[Matrix]

So when you try to shift is it stuck in one position(wont move at all) or when you shift its not grabbing gears?

It just wont move at all. I just took everything back apart and put the crankcase cover back on. The clutch basket and oil filter are out of the case now. Still, the shifter will not move. I am at a loss and I have no clue what to do. I am debating taking it to the honda shop to have it serviced. :(

[Xowner]

Take about 5 pictures of the shifter area on the clutch side. and one picture of the shaft from the left.post them now!

[Matrix]

Take about 5 pictures of the shifter area on the clutch side. and one picture of the shaft from the left.post them now!

Okay, here goes..

148592 148593 148594 148595 148596 148597 148598

[hoosierlogger]

Okay, but why?

Possibly someone here who has done it before can see what you have cocked up.

[Matrix]

Possibly someone here who has done it before can see what you have cocked up.

I thought about that while I was on my way to get some pics and when I got back in I changed it. That was very ignorant of me but its also in the upper 80's and I'm hot as heck and I cant ride any of my trikes :(

[Billy Golightly]

I'm not familiar with those bikes but it looks to me like the whole assembly is "out" too far and needs to be slid back down on an idler shaft or something.

[Matrix]

I'm not familiar with those bikes but it looks to me like the whole assembly is "out" too far and needs to be slid back down on an idler shaft or something.

Thats what I thought but it is stubborn and only comes out slightly not in. Maybe I will try to giggle it in there or something.

[Xowner]

Have you taken the shifter off the shaft? since taking it apart? If you haven't the problem is you have something twisted and not seating correctly.... See how the shifter is twisted up it should be lever with the foot peg so you got to find out why its like that. After that i bet everything falls into place and goes together smoothly. Best bet when you get over heated is to go inside get something cold to drink and relax. Forcing trailprotrailprotrailprotrailpro together is when you break more trailprotrailprotrailprotrailpro and cost your more time and money. Look into why the shifter to pointing to the moon and get back with us.

[Matrix]

Have you taken the shifter off the shaft? since taking it apart? If you haven't the problem is you have something twisted and not seating correctly.... See how the shifter is twisted up it should be lever with the foot peg so you got to find out why its like that. After that i bet everything falls into place and goes together smoothly. Best bet when you get over heated is to go inside get something cold to drink and relax. Forcing trailprotrailprotrailprotrailpro together is when you break more trailprotrailprotrailprotrailpro and cost your more time and money. Look into why the shifter to pointing to the moon and get back with us.

Well I did have the shifter off sometime while doing this but I have the shifter that high so my steel toes can get underneath of it :D. When I had my shifter off I was doing something in the clutch area and the mechanism that is pictured actually slid out a little bit but I was still able to grab hold of the shifter rod and pull it back in. I just got done eating dinner so I'll have a long night looking at this again.

Oh and I do get heated when working on things but once I get heated enough that the usual person will start throwing things, I actually get sad for some reason. I have been inside for quite a few hours today and just moping around on here and YouTube. I just had a box of Kraft mac n' cheese so I'm ready to pull another all nighter!

[Flossyb20]

wasn't tyring to be a d*ck, just trying to see if you did anything else while you had the clutch off...maybe this could be it, was for me

I was still able to grab hold of the shifter rod and pull it back in
There is a small c-clip on the shifter side, right behind the case...if you pull the shifter shaft out too far, the c-clip will come out of it's groove, and could cause the shifter itself to bind up...ran into that problem with my brother's fooler, exactly as you're describing it

[Matrix]

There is a small c-clip on the shifter side, right behind the case...

When you say behind the case do you mean on the inside?

[Xowner]

My next question is do you have a manual? IF it were I id look in the shifting mech on the clutch side something is bound up there. Does the clutch case have any marks on it where its binding?

[Flossyb20]

It's been a while since I worked on a second gen X, but I just pulled up a schematic of your shifter assembly, and looking at the pictures...it look likes shifter plate is in a bind (not letting your shaft all the way in)...is there something in between the fork on your shitfer plate and the shaft...like washer or collar thats on the shift shaft....if I remeber correctly, there should be nothing in between the two plates, but it's easy to let it happen when you slide the fork back onto the shaft.

[Matrix]

It's been a while since I worked on a second gen X, but I just pulled up a schematic of your shifter assembly, and looking at the pictures...it look likes shifter plate is in a bind (not letting your shaft all the way in)...is there something in between the fork on your shitfer plate and the shaft...like washer or collar thats on the shift shaft....if I remeber correctly, there should be nothing in between the two plates, but it's easy to let it happen when you slide the fork back onto the shaft.

Actually I just got back online to say that I may have found a way to fix this issue. There is 1 washer and a collar inside the right side of the crankcase on the shifting mechanism. I removed the collar and washer and put the cover back on to see how the shifter moves and it moves like it should. So, I am going to take the collar out and run a few washers to separate the shifting mechanism while still maintaining the free space needed to let the shifter move. Does that make sense to anyone? I'm not to good at explaining things.

[3wheelrider]

That don't sound like a great idea...-try to see whats really wrong. Rigging it with washers may or may not work well, You may be askin for trouble-its got to be something simple just dont give up.

[Matrix]

That don't sound like a great idea...-try to see whats really wrong. Rigging it with washers may or may not work well, You may be askin for trouble-its got to be something simple just dont give up.

I know its a terrible idea and I shouldn't be doing it but I just cant find out whats wrong. I'm not exactly rigging it but just cutting down on some space by removing the collar and adding a washer. I measured it with the old collar and it save's a slight bit of space so I really hope it will work.

[110klt]

here is a stupid idea, but hey it's an idea. It may be a little work but.......... If you were to reinstall the old clutch does the problem still exist? If you reinstalled the old clutch and it worked then you can rule out everything else but the clutch itself. Then looking it over and ignoring everything else the problem might present itself.

Anyway good luck.

[Flossyb20]

It's not the clutch...no need to pull that back out. Can you get a couple of pictures with the gearshift spindle out. The manual doesn't even show the collar you're talking about, just the washer....I'm wondering where the collar is suppose to go, but the washer needs to go between the spindle plate and the gearshift plate, otherwise you risk bending your shifter plate....post the pics when you get a chance.

[Flossyb20]

take a look at this when you get a chance:
http://www.oscarmayer.net/atc/manuals/

[Matrix]

I put the case and everything back on last night and sealed it up so it will be a while for me to tear everything apart once again. I'll get some pics later today. I downloaded that manual from that site a while ago and its the only thing I have been using. I wouldn't have gotten this far without it actually. But its time to tear everything apart again. I like working on these but when it gets to something like this, its just a hassle to do.

[Louis Mielke]

I see something wrong from the pics. You have something on backwards, there are wear marks visible that technically shouldn't be visible. I know this sounds crazy but parts are meant to go together certain directions. Wear marks also indicate how they were assembled. There is a disk there that has marks worn into the surface, it's the gearshift guide plate, it looks like it should be flipped over. The star pattern is obviously where the drum shifter, and the drum stoper rub against that guide plate. This might not be the true problem but it never hurts to make sure things are back together the way they came apart.


Also there should be a hardened machine washer on the shift shaft before you insert it through the engine, is it there?

[Matrix]

I see something wrong from the pics. You have something on backwards, there are wear marks visible that technically shouldn't be visible. I know this sounds crazy but parts are meant to go together certain directions. Wear marks also indicate how they were assembled. There is a disk there that has marks worn into the surface, it's the gearshift guide plate, it looks like it should be flipped over. The star pattern is obviously where the drum shifter, and the drum stoper rub against that guide plate. This might not be the true problem but it never hurts to make sure things are back together the way they came apart.


Also there should be a hardened machine washer on the shift shaft before you insert it through the engine, is it there?

The gearshift guide plate does have those wear marks on the front for some odd reason but it is on correctly. I pulled the assembly off not to long ago and on the opposite side of the gearshift guide plate there are wear marks from the drum shifter. I never touched this assembly prior to pulling it apart today so it worked like this before but I'm not saying its 100% right, or else it would be working now. There was a maching washer on the gearshift spindle and also a collar. I have misplaced the collar but I'll find it eventually. Thanks for all the help and info guys it does really help out :beer: