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

Non-American model KDX's

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 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?
If you lend someone $20, and never see that person again, it was probably worth it.
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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 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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