How do i remove the lower timing gear on a 2001 xr200r

removing excess oil will be a good start to see if you have a problem. Excess oil causes over heating of the oil and over pressure in the tranny or frothing of the oil which lowers operating pressures in the tranny

Power Steering Gear Replacement
Removal Procedure

1. Raise the vehicle on a hoist.
2. Remove the tires and wheels.
3. Remove the stabilizer shaft links from the control arms.
4. Remove the tie rod ends from the steering knuckle.

5. Remove the intermediate shaft lower pinch bolt from the power steering gear.

1. Remove the stabilizer shaft.

7. Remove the power steering hoses from the from the power steering gear.

8. Remove the power steering gear bolts from the frame.

1. Remove the power steering gear through the left wheel opening.

Remove the serpentine belt, remove the lower crankshaft pulley, place a jack under the oil pan and jack up the engine slightly, remove the engine mount (right top). Remove the timing belt cover, loosen the timing belt tensioner and pull tensioner pulley back toward the rear of vehicle. I like to then tighten the tensioner bolt to hold it in this position, remove and replace belt. If you need to put the engine in time then look at the camshaft there is a small arrow in the center, it lines up with a dot on the end of the cylinder head. The lower timing mark is a small metal tip that sticks out from the lower gear, and it lines up with a notch cut into the front cover just behind the lower gear. Once aligned properly put the belt on the lower gear and without turning the lower gear or camshaft gear pull the belt tight up to the cam shaft the cogs in the belt will line up with the grooves, then place the belt around the water pump drive gear and under the tensioner, then push the belt over all gears by hand without turning the engine. Loosen the tensioner bolt and apply a little pressure toward the front of the vehicle and tighten the bolt. Replace everything else previously removed. Engine should start and run normally.

Open the hood and disconnect the negative battery cable with an adjustable wrench. Wait a few minutes before starting work to allow any current to dissipate. Set the parking brake.

2 Tilt the steering wheel down to the lowest position. Move the gear shift lever to first gear. Leave the key in the ignition. Remove the lower under dash panel plastic clips and screws with a screwdriver. Lift the lower panel upward and remove the upper clips. Disconnect any electrical connections and remove the lower trim panel from the work area. Move the gear shift lever to the Park position and turn the key off.

3 Remove the bolts from the knee bolster plate with a socket wrench and remove the plate from the work area. Remove the two ignition switch bolts using a socket wrench. Disconnect the electrical connector and remove the ignition switch.

4 Install the new ignition switch using the retaining bolts and tighten with a socket wrench. Connect the electrical connector. Install the knee bolster plate and bolts using a socket wrench. Turn the ignition on and move the gear lever to first gear.

5 Connect any electrical connections to the lower trim panel. Install the lower trim panel using the upper clips. Install the bottom screws with a screwdriver and insert the plastic clips. Shift the gear lever into Park and return the steering wheel to its normal operating position. Connect the negative battery cable with an adjustable wrench and close the hood. Release the parking brake. Start the engine to make sure the new ignition switch is operating properly.

Removal Procedure

Notice: Do not rotate steering shaft after steering column has been removed. Damage to SIR components may occur.

Lock the steering column through the access hole in the steering column lower trim cover using the J 42640.
Remove the air cleaner assembly. Refer to Air Cleaner Outlet Resonator Replacement in Powertrain Management.Remove the intermediate shaft shield from the steering gear.Place a drain pan below the steering gear. Remove the pressure and the return hoses from the power steering gear. Cap or tape the ends of the hoses and the gear fittings in order to prevent dirt from entering the system.Remove the lower intermediate shaft coupling bolt. Draw alignment marks on the lower intermediate shaft coupling and the steering shaft. Remove the lower intermediate shaft coupling from the steering shaft. Remove the pitman arm. Refer to Pitman Arm Replacement.Remove the steering gear mounting bolts and the washers from the frame. Remove the steering gear.
Installation Procedure


Install the steering gear. Notice: Refer to Fastener Notice in Service Precautions. Install the power steering gear to the frame washers and the mounting bolts. Tighten Tighten the power steering gear to frame mounting bolts to 75 Nm (55 ft. lbs.). Install the pitman arm. Refer to Pitman Arm Replacement.Install the lower intermediate shaft to the power steering gear. Ensure that the alignment marks line up. Install the lower intermediate shaft coupling bolt. Tighten Tighten the lower intermediate shaft coupling bolt to 35 Nm (26 ft. lbs.). Install the pressure and the return hoses to the power steering gear. TightenTighten the pressure hose to 25 Nm (18 ft. lbs.) for the vehicle equipped with the 2.2L engines. Tighten the pressure hose to 30 Nm (22 ft. lbs.) for the vehicle equipped with the 4.3L engines. Tighten the return hose to 25 Nm (18 ft. lbs.). Install the intermediate shaft shield to the power steering gear. Install the air cleaner assembly. Refer to Air Cleaner Outlet Resonator Replacement in Powertrain Management. Unlock the steering column by removing the J 42640 from the steering column lower steering column trim cover access hole. Bleed the power steering system. Refer to Bleeding Power Steering System in Steering / Service and Repair.

Jack car up, remove drain plug and drain fluid, once it has stopped dripping, remove all the bolts around tranny pan, lower tranny pan, remove the bolt or 2 bolts that hold in the filter. Replace with new filter and new tranny pan gasket and reinstall the bolts.
Then add new fluid, with foot on the brake and vehicle running, shift to each gear for 5 seconds, repeat three times and this will bleed any air out of the system and you will be good to go.

The 2.3 uses a timing belt with an tension idler adjustment. Replacement is straight forward, just make sure to mark upper and lower cog pulleys before removing the old belt so that you can keep the timing in sync.

Remove the serpentine belt, remove the lower crankshaft pulley, place a jack under the oil pan and jack up the engine slightly, remove the engine mount (right top). Remove the timing belt cover, loosen the timing belt tensioner and pull tensioner pulley back toward the rear of vehicle. I like to then tighten the tensioner bolt to hold it in this position, remove and replace belt. If you need to put the engine in time then look at the camshaft there is a small arrow in the center it lines up with a dot on the end of the cylinder head. The lower timing mark is a small metal tip that sticks out from the lower gear and it lines up with a notch cut into the front cover just behind the lower gear. Once aligned properly put the belt on the lower gear and without turning the lower gear or camshaft gear pull the belt tight up to the cam shaft the cogs in the belt will line up with the grooves, then place the belt around the water pump drive gear and under the tensioner, then push the belt over all gears by hand without turning the engine. Loosen the tensioner bolt and apply a little pressure toward the front of the vehicle and tighten the bolt. Replace everything else previously removed. Engine should start and run normally. Hope this helps, let me know.

Had the same problem last month and ended up replacing the gear and it only cost i think 43 dollars or so!