84 honda 200x kickstart problem

[honda200xguy]

so i decided to bust out my project i got last year, which i had almost finished before the snow came. i had a couple hoses i bought from ebay and put them on. the last problem i noticed was the kickstart didn't even seem to be connected on the inside. so i took the little metal panel off the engine where the kickstart is and noticed that the gears/spring for the top rod were gone. i ordered a brand new kickstart spring/gear for it off ebay today. now the thing is, should i crack the case and re-do the gaskets? (bought gasket set anyway) or would it be ok just to put the new spring/gear on there. the bottom one spins but the the top one does not. is that how its supposed to be? help a newbie out !!

[barnett468]

Hello


"the bottom one spins but the the top one does not. is that how its supposed to be? help a newbie out !!"

I have no idea what you are talking about. The gear on the kick starter drives the outermost gear on the other shaft which should NOT spin freely.

Line up drive ratchet as shown in page 10-11.

Your kick starter needs ALL the items listed on page 10-10 in the manual below as shown in the photo.


service manual see pg 10-10

http://www.kb0nly.info/ATC/index.php?dir=ATC200X%2F


Hope this helps.

[dougspcs]

You are in for a pretty big fix..there is a ratchet in the heart of the transmission on the kicker shaft. The gears on it are worn and won't engage anymore..

Then engine has to come out and the case split..then the part listed in the other new member thread replaced. A full gasket set is needed and since you're there you might as well do a top end refresh to complete the rebuild..

It's a common issue and a deal ender for any early 200x I look at..if the kicker slips even once out of 10 kicks, I walk away.

Someone with engine overhaul experience is a must! But do it right and it's good for another 25 years.

[honda200xguy]

You are in for a pretty big fix..there is a ratchet in the heart of the transmission on the kicker shaft. The gears on it are worn and won't engage anymore..

Then engine has to come out and the case split..then the part listed in the other new member thread replaced. A full gasket set is needed and since you're there you might as well do a top end refresh to complete the rebuild..

It's a common issue and a deal ender for any early 200x I look at..if the kicker slips even once out of 10 kicks, I walk away.

Someone with engine overhaul experience is a must! But do it right and it's good for another 25 years.

Yes, the bottom shaft spins freely, the top one does not...
Those links don't work


You are in for a pretty big fix..there is a ratchet in the heart of the transmission on the kicker shaft. The gears on it are worn and won't engage anymore..

Then engine has to come out and the case split..then the part listed in the other new member thread replaced. A full gasket set is needed and since you're there you might as well do a top end refresh to complete the rebuild..

It's a common issue and a deal ender for any early 200x I look at..if the kicker slips even once out of 10 kicks, I walk away.

Someone with engine overhaul experience is a must! But do it right and it's good for another 25 years.

Im going to do both the top and bottom end probably.

is this the correct piece? (besides its for a 85)
http://www.ebay.com/itm/Honda-ATC200x-ATC-200x-Kick-Start-Shaft-OEM-Great-Shape-seat-tank-fender-/160998390212?pt=Motors_ATV_Parts_Accessories&hash=item257c4079c4&vxp=mtr

[yaegerb]

so i decided to bust out my project i got last year, which i had almost finished before the snow came. i had a couple hoses i bought from ebay and put them on. the last problem i noticed was the kickstart didn't even seem to be connected on the inside. so i took the little metal panel off the engine where the kickstart is and noticed that the gears/spring for the top rod were gone. i ordered a brand new kickstart spring/gear for it off ebay today. now the thing is, should i crack the case and re-do the gaskets? (bought gasket set anyway) or would it be ok just to put the new spring/gear on there. the bottom one spins but the the top one does not. is that how its supposed to be? help a newbie out !!

"so i took the little metal panel off the engine where the kickstart is and noticed that the gears/spring for the top rod were gone."

What metal panel did you take off? The small one that exposes the two offset gears or the clutch cover? There is no way you would have seen the return spring with the kick starter panel removed. If you are missing only the counter gear set then why did you go buy the entire kick starter assembly?

Pics would really help.

[honda200xguy]

"so i took the little metal panel off the engine where the kickstart is and noticed that the gears/spring for the top rod were gone."

What metal panel did you take off? The small one that exposes the two offset gears or the clutch cover? There is no way you would have seen the return spring with the kick starter panel removed. If you are missing only the counter gear set then why did you go buy the entire kick starter assembly?

Pics would really help.

I cant take pics right now, im at work. but yes i took off the one that exposes the two offset gears. the top gear is missing, i guess i didn't know the spring would be on the inside. well yea is it only supposed to be the counter gear on the top or is the other parts supposed to be exposed also?

[yaegerb]

I am pretty sure you are missing part number 3 within the link below. Make sure to double check your manual to ensure that's the right gear you need to purchase before you buy.

http://www.bikebandit.com/houseofmotorcycles/1985-honda-atc200x/o/m1899#sch10227

[jwilz]

A lil OT but i have also have the 84 200x and i've read about the crappy starter gears and the fix u gotta do. Mt question 4 anyone who might know- my trike kicks and starts. maybe like every 3rd kick it slips halfway and then kicks fine again for another 3 kicks. Im figuring this is the common issue everyone has with these but i just got done a engine rebuild and wasn't aware of this at the time so it was overlooked. I really dont see myself being committed enough to immediately splitting the cases again to fix this. Just wondering if anyone has any idea whether the kicker is gonna go and fail sooner or later or if it will just keep skipping every 3rd time? Cus ill happilly leave it.

[yaegerb]

A lil OT but i have also have the 84 200x and i've read about the crappy starter gears and the fix u gotta do. Mt question 4 anyone who might know- my trike kicks and starts. maybe like every 3rd kick it slips halfway and then kicks fine again for another 3 kicks. Im figuring this is the common issue everyone has with these but i just got done a engine rebuild and wasn't aware of this at the time so it was overlooked. I really dont see myself being committed enough to immediately splitting the cases again to fix this. Just wondering if anyone has any idea whether the kicker is gonna go and fail sooner or later or if it will just keep skipping every 3rd time? Cus ill happilly leave it.

It will eventually fail. Enjoy it for a year and then replace the kicker gears and springs. In the mean time, keep a look out on Ebay for new kicker gears and springs. I mean new, NOS, not used ones.

Or you can click on the link above that I posted and order new gears from bike bandit. Unfortunately 7 and 10 (springs) are discontinued so you are back to Ebay.

[jwilz]

thanks that kinda what i figured. Hopefully it holds until i need new rings again so I'll be back in the case anyway.

[honda200xguy]

http://www.ebay.com/itm/84-1984-HONDA-ATC200-ATC-200-X-START-STARTER-SHAFT-DRIVE-DRIVEN-GEARS-AND-COVER-/380369015892?pt=Motorcycles_Parts_Accessories&hash=item588fc29454&vxp=mtr

this is the correct item, right?

[yaegerb]

yep, that's what you need.

[honda200xguy]

yep, that's what you need.

so would i be able to tell (for next time) if the gears on the inside are broken?

[yaegerb]

so would i be able to tell (for next time) if the gears on the inside are broken?

Well, once you get the external kicker gears back together you will be able to tell real quick whats working and not working ;)

matter of fact, I would just put it together with some assembly lube, bolt it together and kick it over to see if it works. That way you won't ruin the gasket and have to buy another gasket if you find something isn't right.

[honda200xguy]

Well, once you get the external kicker gears back together you will be able to tell real quick whats working and not working ;)

matter of fact, I would just put it together with some assembly lube, bolt it together and kick it over to see if it works. That way you won't ruin the gasket and have to buy another gasket if you find something isn't right.

thanks for the help bud.
ill post back when i get the gears in the mail!

[Gates72ss]

all too common on the old 200x , Had the same problem on a project of mine ended up just waiting and finding all new honda parts and haven't had 1 issue since..

[Howdy]

Gosh I wished I had seen this thread before you bought those gears. I would have sold you them for $16 shipped.
Howdy

[honda200xguy]

Gosh I wished I had seen this thread before you bought those gears. I would have sold you them for $16 shipped.
Howdy
oh man lol
damn