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

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If you are referring to the crankshaft timing gear then they are held on by 2 methods. The first method is a slide on fit over a long key and retained in place by the tension on the pulley nut
The second is a press on fit over a key and will have ( generally 2 threaded holes in the face with which to attach bolts and a puller. In the first case ,if the gear will not slide off with gentle persuasion, leverage or heat the you will have to use a bearing puller over the back of the gear to pull it off

Posted on Dec 12, 2014

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Posted on Jan 02, 2017

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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.

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