2002 Honda XR 200 Logo
Posted on Mar 16, 2009
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02' XR200 won't shift into any gear

I let a friend ride my bike and he called me saying it wouldn't go into gear. I don't think he was using the clutch like he was suppose to. Now the bike won't go into any gear, even though it sounds fine when I up and down shift it. I'm not totally sure what I'm looking at when I opened the right side case? Any help?

1 Answer

tombones

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  • Master 3,567 Answers
  • Posted on Mar 17, 2009
tombones
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Joined: Mar 11, 2009
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With the right side case removed, you will see the shifter shaft with an arm attached to the shaft and at the end of the arm will be a 1.5" long lever, ( called a "pawl" ), with a kind of hook on each inside end. There should also be a small spring attached to the lever. The lever should be engaged to a round shaft of about 1.5" diameter. The shaft I just mentioned is actually the end of the shift drum.
....
On rare occasions the spring will break or get out of place. Check it out. Another possibility is that the shift drum may have dropped a pin or two. The pins I refer to are what the pawl pushes or pulls on to rotate the shift drum. Move the foot shift lever up and down and you should see the mechanical action I'm referring to. IF I remember correctly, your bike has a drum that could allow a pin or pins to drop out if the end cap on the drum comes loose. No pins = no shifting.
....
Check things out and post a comment as to what you find out. Also, any other questions you may have after looking at the stuff mentioned. When all is done, please post a rating of my answer. Thanks.

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http://www.parktool.com/blog/repair-help/shift-levers-shifters

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