KDXRIDER.NET

Ok, I picked up a 89 KDX-200 and promptly took it completely apart because we were going on a big ride Labor day weekend. Ordered all kinds of things to bring it up to speed - new swing arm bushings/etc..
I now have a shifter problem - here is the background:

It had a clutch problem,(not releasing), so I had pulled the entire right cover off and had the clutch out checking things out.
At one point, the springs/etc on the shift lever popped off. Not a problem, I have the Factory Service Manual and I re-installed them. It shifts fine up and down.
When I tighten down the right side cover - it gets very stiff - something is rubbing and preventing normal shifting. I pull the cover back off - it will shift fine.
Ideas?

Pull back out the springs/etc. There's a flanged washer in there somewhere. Make sure the flange is such that the hole in the little shift arm thing seats over the flange. If you have it backward the whole thing sticks out a few mm too far and you will have the problem you describe.

I see the flanged washer in the parts diagram. Definitely a possibility and I'll check.

Same thing happen to me recently. It was the shaft collar (ie;flanged washer) that was the problem.

I remember specifically because we had the same problem buttoning up a kx100 i rebuilt for a friend recently.

BTDT

Thought my gasket was the suspect

6 fugging quarts of oil later....

As a follow up, that was exactly the problem. Got it centered and it worked great. Thanks for the tip.