Page 1 of 1

1997 KDX200 - After complete rebuild, won't select neutral

Posted: 06:34 am Feb 13 2018
by ianp
Hi Guys, after having split the case to replace crankshaft seals and all main bearings, I have re-assembled the motor, all seems good, the motor runs but I cannot select neutral. Anyone have any suggestions that will avoid having to split the case again?

Re: 1997 KDX200 - After complete rebuild, won't select neutr

Posted: 07:56 am Feb 13 2018
by Timtee
Try rocking the bike forward and backward a little while trying to find neutral.

Can you get into all the other gears?

Re: 1997 KDX200 - After complete rebuild, won't select neutr

Posted: 01:13 pm Feb 13 2018
by KDXGarage
Welcome to kdxrider.

Is everything reinstalled correctly on the right side, under the clutch?

1997 KDX200 - After complete rebuild, won't select neutral

Posted: 02:38 pm Feb 13 2018
by Molly's 70
Does it shift into all 6 gears?

Re: 1997 KDX200 - After complete rebuild, won't select neutr

Posted: 02:55 pm Feb 13 2018
by KDXGarage
neutral return spring?? (someone will be along soon that has been in there recently)

Re: 1997 KDX200 - After complete rebuild, won't select neutr

Posted: 11:28 pm Feb 13 2018
by doctord23
I can't think of a reason why you can't find neutral.
You can pull off the clutch side cover and force it into neutral position to check that you are hitting the spot.
My only other thought is that you have something too tight inside.
Did you verify that you installed all of the shims?

Re: 1997 KDX200 - After complete rebuild, won't select neutr

Posted: 12:42 am Feb 14 2018
by ianp
Thanks for the suggestions, I have tried rocking the bike back and forth with no joy. I will remove the side cover to see if I can select neutral manually. The Neutral return spring I'm not sure about (this was my first attempt at stripping a motor so have still a bit to learn :wink: ) - ofcourse today being valentine's day means no time for the bike tonight :twisted: )

Re: 1997 KDX200 - After complete rebuild, won't select neutr

Posted: 06:41 am Feb 14 2018
by Timtee
Can you shift into all the other gears?

1997 KDX200 - After complete rebuild, won't select neutral

Posted: 07:08 am Feb 14 2018
by ianp
Hi Timtee, yes, no problem selecting all other gears.

Re: 1997 KDX200 - After complete rebuild, won't select neutr

Posted: 11:17 am Feb 14 2018
by ohgood
Tighten the shift drum bolt if its loose and reinstall the tensioner spring.

1997 KDX200 - After complete rebuild, won't select neutral

Posted: 02:07 am Feb 21 2018
by ianp
OK, so I finally had a chance investigate. Turned out to be an amateur error : :oops: roll: . I neglected to insert the locating pin between the shift drum and the turret (I think that's what it is named). I managed to do all the necessary without having to remove the main side cover :boogie: I however saw that there are 3 locating holes in the bottom of the selector drum?? not sure why that is... Anyway by a bit of logical deduction managed to get the correct hole on the 1st attempt.

While I had the clutch set off, I played around with it a bit to try see why it wouldn't release with the clutch pulled in, with that something must have gone wrong as when I put it back in, the distance from the clutch release pin and the actuator cam had increased, so pulling in the clutch didn't do anything. :cry: Oh, well the main issue is sorted, the new issue will I think be an easy fix.

I would be interested to know why there are 3 locating holes in the bottom of the shift drum.... :hmm:

Thanks for all the input.. :supz:

Re: 1997 KDX200 - After complete rebuild, won't select neutr

Posted: 04:46 pm Feb 21 2018
by bufftester
Double check that you got all the spacers and shims back in the correct order with respect to the clutch basket installation, that is generally where most folks make a mistake.