200s clutch shifting problem.

[hoosierlogger]

I looked in the world class help section and did a search in the search box. I didnt find what I was looking for in the first 5 pages. So here goes, I took my clutch plates out and took some emery cloth to them to get rid of the glazing on the discs from the previous owner. The bike was slipping when you shifted into third, and wouldn't grab in fourth or fifth unless you let off of the throttle and slowly eased back in to it. I put her all back together, adjusted the clutch nut and screw according to the manual. Now the clutch grabs like a brand new one, but there is no longer a "neutral" in between each gear. When you shift it is similar to shifting a manual without using the clutch. Even if you shift from first to second and hold the lever up with your toe it still runs along just like you let off of the shifter.

Has anyone else done this before? I know I cant possibly be the first person who this has happened to. Anyone have any pointers?

[1984 honda 200s]

my ol 200s was like that too one day when i took it for a ride, it always slips on cold take off due to thick oil, but one day the nut and sealing washer fell off :O and it was like shifting with no clutch.
Id say loosen the lock nut and turn the adjusting screw (counter clock wise) untill you feel resistance then back it off (clock wise) 1/4 turn and try it out, should work unless the clutches are much more worn or something worse. hope for the best. a shop manual would be a good help too.

[hoosierlogger]

Yeah I have read the manual, but it didnt say anything about that particular problem. I read over the entire clutch section of the book. The clutch adjuster was adjusted just like the book and you suggested. One of the aluminum tabs on the clutch basket got broke off during removal when it hit the floor of the shop. But I dont see how that could cause this problem. The only thing I can think of was I put the ball and ramp assembly in wrong somehow.

[1984 honda 200s]

I would say adjust the screw all the way (counterclock wise) and try it, if theres still nothing grabbing then i would take that appart and look it over, if you figure the ball and ramp is in wrong, check it over to make sure, maybe you got a clutch disk in wrong some where, sorry im no expert in 200s clutches :( Hope some others have an opinion or 2. Good luck!

[hoosierlogger]

I played with it earlier and got it to work right in between first and second. It is not as bad as it was in the rest of the gears. I readjusted the clutch after I rode it a good bit and had to move the screw about 1 1/2 turns till I got resistance. Maybe there was some grit or something on the screw that gave me a false feeling of resistance. Or perhaps the clutch plates are "setting in" after being roughed up. I dont know, but it is shifting easier now.

[1984 honda 200s]

ahh there ya go, your getting somewhere now!! it always best to adjust them when the engine is hot. maybe once you ride it more the plates will set in more. maybe you can go 2- 2 1/2 turns on the adjuster now, worth it to try. Glad to hear its getting better.