Question about 2002 Honda XR 200

6 Answers

I have a 85 Honda xr 200. I was changing the oil and accidently removed the case bolt behind the drain plug. I realized I had the wrong bolt so replaced it and then removed the drain plug. In the process the shifter lever went limp and after the oil change the bike would not shift beyond 2nd gear and feels loose. I'm afraid that removing and then replacing the incorrect case bolt caused the shifting problem. Help....... Can I correct my error without removing the entire case??

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  • Brian Peters Nov 08, 2010

    I was able to hand thread the bolt back in without any resistance so I doubt anything warped. The bolt I remove was threaded next to the hex head and had a smooth shaft with a machined groove in it. I never completely removed the bolt when I realized this was not the drain plug. ( I was able to see about 2 inches of the bolt) I' fell like it was somehow connected to the shifter mechanism as it was just in front of the actual shifter shaft that comes through the case. Can it be realigned by moving the shifter and if so How?? I can still shift into first, neutral and second, but the shaft feels limp and loose.

  • Brian Peters Nov 09, 2010

    I completely removed the bolt that I had inadvertently removed during the oil change. It is a 3 inch long smooth shaft and the end of the shaft is pointed almost like a sharpened pencil. This is a 10x12 bolt. It limits the up and down travel of the gearshift spline but must do more. The schematics I look at don't show any connection to anything like a spring or another component but the schematic are broken up into shifting components and crankcase components so I can't see exact assembly. Has anyone disassembled a older Honda transmission/shifting spine and is familiar with the components. After putting things back together I started the bike up and I can smoothly shift into first, neutral and second, but will not go above second. The shifting and downshifting is smooth and quiet?? The idea of pulling the right side with the clutch and all the gearing out just to get to the left side is not pleasant. I can look into the left crank case hole when the bolt is out and could move components around but not sure what needs to be aligned?? I can't be the only one with this experience....

  • Brian Peters Nov 10, 2010

    Actually I can look through he case opening and see the top and bottom of the gearshift spine and move it by moving the shifter lever. My bolt or shaft has slight wear spots where the shifter spline has been hitting it over the years. I can align it perfectly between the top and bottom of the shifter spline but I feel the end of the shaft that is pencil tip shaped must fit into something that is not attached. Someone who has been in this type of transmission would know exactly why the end is machined to a point? possibly another shaft or something attaches and is off???

  • Brian Peters Nov 13, 2010

    Has anyone else worked on a 200 xr transmission and what needs to be reattached to the shaft I described? Is it accessible from the right side and what has to be removed to get to the left side.

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6 Answers

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  • Honda Master
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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

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  • Master
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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

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  • Honda Master
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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

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  • Master
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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

  • David Belcher
    David Belcher Nov 09, 2010

    Many repairs on motorcycle engines are made from the opposite side of the motor. The engines are small with removable panels , so you have access. You can not make a repair if you do not look to see what the problem is.

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  • Honda Master
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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

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  • Honda Master
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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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