Subtranny won't shift correctly. 82' 200E

[supernova1021]

OK, putting my subtranny back together again after changing the front sprocket out on my 82 Honda 200E. Went back together easy enough (have a manual) and put the cover back on. As soon as I tightened up the bolts on the cover, the hi-lo gear shifter got very tight. It shifts fine as long as the bolts are just finger tight. As soon as you put the socket to them, it stiffens up to the point you cannot shift it from hi to lo by hand. Broke it back down several times and everything is in place correctly.

Thinking maybe the shift drum shaft is bent or maybe the shift fork shaft. Strange though because it shifted fine when I took the thing apart to change the sprocket out. But now I have to replace the shift drum anyway because the threaded end where the lever connects broke off. Dunno.

Anyone with a 200E ever have this happen when putting your subtranny back together again?

[supernova1021]

Only thing I know to do is to replace the shift drum and the shifter fork and shaft... Hell, maybe they did get bent somehow.

[oscarmayer]

if you put the sift fork pin on backwards it will cause this. I have to tell ya the sub trans re-assembly is a beast a times. if you don't get it jsut right on assembly it won't work. something eitehr fell out during reinstall or it's backwards. i'm fuessing the shift fork and or oin are in backwards or not even proeprly installed. common mistake.

in my sig is a link to manuals. the factory manual is there. the 125m and 110 have the same sub trans. shaped differenly but insides go together the same way.

[supernova1021]

Hmmm... Well, I have the manual for it and not sure how it could be installed backwards really. The fork knob that slides in the shift drum would be on the opposite side if it were installed backwards right? Yeah, definitely a PITA.

[MTS]

Is the gasket in there? Some set ups need that clearance To work properly when tightened down, Assemble the shafts with some oil too

[supernova1021]

Well it did have a gasket (normal thickness) but I just cleaned the edges good and squeezed some form-a-gasket on it when I put it all back together. Just wouldn't think a gasket that size would make a difference really.

[Pafrig]

MAybe you just put too thick of a washer in somewhere?

[supernova1021]

MTS, the more I think about it the more sense that makes. I'll get some decently thick gasket sheet, cut one out and put it on there. See what happens.

All the parts that came out went back in and it worked fine when I took it apart.

[oscarmayer]

no the fork drum can go on the slide 2 ways. there's also a ball with a spring inside the fork slider so make sure thise are also there. there's 2 notches on the fork slider pin. those both need to be closer to the sub trans housing than the engine side. otherwise it's backwards. i bet you got the fork on upside down. and yes you can out it on upside down the ball side goes closer to the engine side.

also make sure you instlaled the thrust washers correctly.als the pins didn't get stuck halfway int to bearing.

[supernova1021]

Yeah, I know exactly what you are saying there. The manual showed how it needed to go, notched side away from engine. The ball and spring are all intact. Telling ya, I have been through that thing two dozen times now! I will double check the thrust washers again.

I did cut a gasket for it last night and put it on like MTS suggested and it shifts fine when torqued down. Still strange though, I have another 200E and looked at the subtranny on it. It looks like it does not even have a gasket between the housing and case. PITA!!

[MTS]

Yeah, I know exactly what you are saying there. The manual showed how it needed to go, notched side away from engine. The ball and spring are all intact. Telling ya, I have been through that thing two dozen times now! I will double check the thrust washers again.

I did cut a gasket for it last night and put it on like MTS suggested and it shifts fine when torqued down. Still strange though, I have another 200E and looked at the subtranny on it. It looks like it does not even have a gasket between the housing and case. PITA!!

Glad i could help, Castings Very somewhat from one to another, machining too, Most are built within a range of a measurement- long as its in there it pass's...not uncommon on older built stuff.

[oscarmayer]

if you have to have a gasket, there is gunk in the case side pin shaft holes and it's pushing the slider pins out. i had to take a scribe and gently scrape the edges of the hole out and then use qtips to clean it. once cleaned it was perfect. before that I had issues with it wanting to seat.

glad you got it!

[supernova1021]

Yeah, glad I got it too.. Thanks for everyones help. Took my 83' 200E out for the first time to really ride today and the damn chain came off of it about five minutes into the hard ride. Now I know what I am doing on New Years Day... Checking the sprockets and chain!

[Dirtcrasher]

Hey, it's just like the 200X. If you leave out that .020 gasket between the kicker case and clutch cover case, it won't kick smooth. In some cases the kickstarter will not even return to the upright position!!.......

[oscarmayer]

^ good to know DC about the kicker i was goign to start redoing anotehr 200x and was debating if I needed the gasket or not.

[Dirtcrasher]

:D I was a blue silicone lover when I was a teenager. Now, just about any engine I build/work on (unless it's been scored/scratched/ruined by a meaball) I rarely use any silicone at all. Silicone works great on threaded tapered connections like your air compressor fittings. Aside from that, I only use it when I see a screwdriver gouge on a side case cover.

I'm a big fan of using grease on my gaskets (aside from the head and cylinder base gasket) and I like using 3bond or Yamabond on all my rocker boxes.........

OT - But, one of the biggest mistakes is when people use silicone on automatic transmissions during an oil and filter change which require the pan to be dropped. If ANY of that silicone breaks loose, it gets in the valve body and thats the end of that transmission.

Silicone has it's place, just not at MY place, :lol: Happy New Year guys!!