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

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

Postby ianp » 06:34 am Feb 13 2018

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

Postby Timtee » 07:56 am Feb 13 2018

Try rocking the bike forward and backward a little while trying to find neutral.

Can you get into all the other gears?
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Re: 1997 KDX200 - After complete rebuild, won't select neutr

Postby Jason » 01:13 pm Feb 13 2018

Welcome to kdxrider.

Is everything reinstalled correctly on the right side, under the clutch?
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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1997 KDX200 - After complete rebuild, won't select neutral

Postby Molly's 70 » 02:38 pm Feb 13 2018

Does it shift into all 6 gears?
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Re: 1997 KDX200 - After complete rebuild, won't select neutr

Postby Jason » 02:55 pm Feb 13 2018

neutral return spring?? (someone will be along soon that has been in there recently)
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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Re: 1997 KDX200 - After complete rebuild, won't select neutr

Postby doctord23 » 11:28 pm Feb 13 2018

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

Postby ianp » 12:42 am Feb 14 2018

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

Postby Timtee » 06:41 am Feb 14 2018

Can you shift into all the other gears?
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1997 KDX200 - After complete rebuild, won't select neutral

Postby ianp » 07:08 am Feb 14 2018

Hi Timtee, yes, no problem selecting all other gears.
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Re: 1997 KDX200 - After complete rebuild, won't select neutr

Postby ohgood » 11:17 am Feb 14 2018

Tighten the shift drum bolt if its loose and reinstall the tensioner spring.
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1997 KDX200 - After complete rebuild, won't select neutral

Postby ianp » 02:07 am Feb 21 2018

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

Postby bufftester » 04:46 pm Feb 21 2018

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.
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