Question about 2002 Honda XR 200
Sorry their is a lever behind the case for the gearchange and if your lucky you may be able to locate it with a thin screwdriver IF YOUR LUCKY if not then its the casing off to reset it again ,and when you do it mark the drain plug with some white paint because if your like me by the time i come to change the oil again i will have forgotten and do the same mistake all over again ,and how do i know this ?? easy i have it done it twice on one of my old bikes many moons ago
Posted on Nov 13, 2010
Hello Peter. You are correct in stating that your actions caused the shifter lever problem. You will have to remove the case in order to reconnect the shifter lever. This is a difficult job so unless you are mechanically inclined, it would be best to leave this repair to the pros. Joe
Posted on Nov 10, 2010
Unless you get a miracle it is impossible to realign the bolt with the shifter- you can try - removing the bolt - moving the shifter up or down and reinserting it but this is a real shot in the dark,
Best of it
Gary @ Fix Ya
Posted on Nov 09, 2010
You may be able to correct the problem by taking off the right side cover and working from that side . Be sure to clean as much dirt from the motorcycle as possible before starting work. A good pressure wash will help keep dirt out of the interior of the motor. You still may have to disassemble a few internal components to get access to the left side of the case. If you can not fix it from the right side at least you will have a good start to splitting the cases , if need be. You can look at expanded parts diagrams of the inside of your engine at ( bikebandit.com.). My guess is that if something shifted (a spring unhooked) You may be able to access it from the other side , remove the bolt , put it back in place , replace the bolt , and fix the problem. At least if you look in the other side it may help you figure out if you have to remove the motor or not. If you can fix it form the right side you may only be out a $10 gasket.
Posted on Nov 08, 2010
Apparently when you put the wrong bolt it has caused the case to become warped or out of position and this has loosened (or popped them completely out of position)the links in the shifter shaft. The only thing you can do from the outside is to try to realign the links by messing with the lever and the position of the case until the lever feels right and then tighten the case .
But, to be honest, i doubt you will succeed this way - the gearbox will have to be dismantled and all the linkages realigned.
Posted on Nov 07, 2010
If the shifter lever went limp, then the hydraulic fluid may be low if it has a hydraulically actuated clutch. Check the fluid level at the lever to make sure there is brake fluid there and add if necessary.
I'm not sure which bolt you removed and replaced based on the description.
I happen to have an '85 Honda Interceptor that has never had this problem, so I am not sure.
I noticed that the picture is of a dirt bike, but the principles should be the same.
Hope this helps.
Posted on Nov 07, 2010
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Posted on Jan 02, 2017
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