XR200R shifting problems

[John Keiser]

I'm stuck!

I bought a 99 xr200r for $500, guy said it ran fine but couldn't get it into 1st or neutral. I looked it up and figured i'd have to do the star and plate replacement. I rode it a couple days without a first gear or neutral and it was running great. The last day it started not wanting to shift down from the upper gears. Like an idiot i really tried stomping on it a few times before realizing it took a very light touch to get it back down. Anyway I tore it apart, replaced the star and plate, thought I had it running through all the gears so I began to put it back together. I ended up snapping the clutch hub while tightening so I had to order one. Once that came and I went to reassemble again, I couldn't get the thing to cycle through the gears! Now it goes through 1-N-2-3, but will not continue into 4-5-6. After inspection i can see that the gear drum (the thing the star bolts onto), will not rotate more than about 170 degrees. Thus why i can only access about half the gears. I am now at a loss as to what to do. This is my first time tearing into a bike like this and I'm trying to avoid taking it to a mechanic but... I don't wanna split the case without even knowing what parts i'm looking to inspect/replace.

Any tips? SEE VIDEO ATTACHED

TIA

IMG_1377.png

[smokemifyagotem]

Sounds like you need shift forks. Had a similar issue with my 95 XR200. You could tell be the tire wear that the thing had been used previously really hard and a lot of wheelies and highway speed riding. Turned out that my shift forks were worn down below service spec. I believe the wear spec is 4.5 mm minimum. It is a case split type repair. If you can do a top end then you can do this at home. I did.

[John Keiser]

Yeah I think you're right about the shift forks. I was watching a video (

) and at one point the guy has to 'wiggle the chain' to get it into the next gear. I also read that it's not uncommon for a bike to not shift properly on the bench, it needs to be oiled and hot and gears moving around for things to shift properly. dSo i tried rolling my bike forward and backwards a little bit to see if i could get it into the higher gears. I never got it into any higher gears but I was able to make it worse to where I could only access 1 or 2 gears. But i'm pretty sure now that I was getting it into all the gears before I tried to reassemble the first time. So now i'm wondering if i should reassemble and see if it works any better than on the bench? or just go ahead and replace shift forks? 

[John Keiser]

Are forks parts 1, 2, and 3 in this diagram? 

[smokemifyagotem]

Yes those are it in the diagram. Before I replaced mine I looked up the part numbers on Babbitt's and then searched the numbers on eBay. Since Honda didn't make them anymore for my 95 I sound up getting an entire used set and checked them for wear. All were useable so it worked in my favor. I would use an good blown up diagram like you have and check all of your assembly, if good I'd go into the cases and replace the shift forks.

[smokemifyagotem]

The NOS shift forks for the 95 were around 75.00 a piece and I couldn't Locate one of them anywhere. That's why I bought a used set

[John Keiser]

Thanks! I'm looking to dig into this thing today. I've got forks and a drum from eBay. I've got service manual PDF's but i'm honestly not sure what has to come off and in what order? I can't find any walkthroughs or video either, any chance you wanna give me a quick rundown of the process? 

[smokemifyagotem]

I've got to find my cycle pedia for it. Let me look for it. It has step by step instructions in it

[smokemifyagotem]

Ok, so I know where it is and I will have to go and get it tomorrow. It's in my storage unit because I just moved. I will get back to you in the morning sometime.