Hi,
I pulled the motor out of my '84 200M to rebuild. While looking at the engine I found that the countershaft sprocket has a fair bit of play on the splines. Not enough to strip it, but I have a feeling its ing on accel/deceleration. Question 1 is: is there a thicker sprocket or something like that to engage the rest of the good splines that I could install??
Since I am going to be rebuilding the top end, it doesn't make sense to do a hack job on this critical piece. So question 2 is: what does it take to split the cases? Do I need any special tools? Is it hard to get the transmission back together? I am pretty handy mechanically but never been this deep into an ATV motor before. I plan on documenting the process and having a build thread, as I havent found a nice thread with pictures for the ATC200 in my searches.
I'm pretty sure I have a spare countershaft, but does anyone know where I might be able to find a NOS one??
Heres a few pics. You can see the gap between the sprocket and spline teeth.
Also the countershaft does have a small amount of in-out movement, but no lateral play.