200s shift shaft installation verify

[webbch]

I had to replace the transmission countershaft on my '84 200s as the PO had run it without screws in the sprocket and it wallowed out the shaft. So I split the cases and did that work (also had it bored the next size up as it appeared to have been run w/o oil). I got it all back together, adjusted the clutch to ensure the shifter had some free-play before going into the next gear, and drove around the yard for about an hour with the kids, at which point, I shifted into neutral and was no longer able to shift anymore. There was also no longer any free-play in the shift lever either. I looked down and noticed the clutch adjuster locking nut had backed out, but it was so tight that I couldn't adjust it with a flathead screwdriver.

I popped the clutch cover off and was then able to shift through the gears, but I also had trouble remembering exactly how the shift shaft is installed during my previous re-assembly, and the manual didn't give enough detail on this step to make it clear. I thought I'd ask you guys to verify that I installed the return spring correctly on the shift shaft.

Here's the basic area that I'm working in:
http://img.photobucket.com/albums/v708/webbch/Misc/ShiftShaft_01_zps98367c38.jpg (http://smg.photobucket.com/user/webbch/media/Misc/ShiftShaft_01_zps98367c38.jpg.html)


This is how I'm installing the return spring on the shift shaft
http://img.photobucket.com/albums/v708/webbch/Misc/ShiftShaft_02_commented_zpsd8f6cf87.jpg (http://smg.photobucket.com/user/webbch/media/Misc/ShiftShaft_02_commented_zpsd8f6cf87.jpg.html)

...And here is where I'm installing the ends of the return spring in the case
http://img.photobucket.com/albums/v708/webbch/Misc/ShiftShaft_03_commented_zps82b114ea.jpg (http://smg.photobucket.com/user/webbch/media/Misc/ShiftShaft_03_commented_zps82b114ea.jpg.html)

If that checks out, I'm just planning to re-install, adjust the clutch, and this time make sure I tighten the locking nut securely. Thanks.

[tri again]

Nice post, great pix.
Sorry no one has responded.
I've been into a few but it's been a couple years.
I usually unplug the phone and take lots o' pictures and sometimes that doesn't even help.

How about a parts diagram from say, bikebandit?
At least it would show you the 'sequence'.
Maybe also try the search key on here for shift shaft. or 200s shift shaft.

On the 250 models, I remember a thin flat thrust washer on the other side of the engine so I'd lay the trike dead level so whatever was on the other side cover would stay put when I pulled the shift shaft out.
NOT to ruin your day, but something to look for in the parts diagram.

[webbch]

I actually took lots of pictures during disassembly, but once the shift shaft is actually installed in the case, it's very difficult to get a good picture of it...even if you're trying to. From the sources you state as well as the manual, I'm pretty confident the stackup is correct. What they fail to show is the details of HOW the spring is installed on the shaft and into the case. I THINK I have it right, but figured someone on here who's done it a few times could give me the thumbs up - it's a bit of a pain to dig in that far to fix it if it's wrong.

[tri again]

I'm sure it's been done tons of times.
Lots of folks are still on vacation but surely someone will jump in.
I've found that most things only go one way, or the cover won't go on easily.
You might get away with trying it, no gaskets or oil and set the cover on loosely
and see if it shifts ok with ez hand pressure.

I got stuck bad into an sx shift issue and it was for my daughters birthday,
very special and included trips to and from Canada so I kinda know the feeling.

Wish I could help more.
IF I have one in the barn, I could try and buzz the cover off in the next few days and walk you through it or even with a phone call while I'm doing it would be ok too.

Search key didn't help at all?
We got tons of pix and posts about the sx shift issue a few of us went through at the same time.

[webbch]

Late Update:
The shaft appears to be installed correctly. I believe the issue was with the clutch adjustment mechanism:
http://img.photobucket.com/albums/v708/webbch/Misc/ClutchAdjuster_zps4420cd92.jpg (http://smg.photobucket.com/user/webbch/media/Misc/ClutchAdjuster_zps4420cd92.jpg.html)

I noticed during re-assembly that if the clutch adjustment gets too loose, you can actually get the ball retainer (#15) to index out of it's detents in #8 and #9, and the clutch disengagement mechanism no longer performs it's function, and trying to making clutch adjustments via the screw on the clutch cover (#14) is futile.