1985 200x 2nd Gear Issue

[Chickenhawk327]

Ok so I pulled apart my 200x a while back because I seized it up, so ordered new piston crank etc, etc git it all out it back together yesterday and when I was riding it, breaking it in I noticed 2nd gear slips in and out for a bit then just drops in to neutral, read a few other posts and most say all gears do it. After breaking it in I started to ride the hell out of it and sure enough its only second gear, I didn't pull apart the gear assemblies but did split cases and of course first couple gears/shims fell off, thought I has them together correct, guess not. Kinda lost going to pull it apart on Friday and see what I can find, any ideas? Shim missplaced? Also pulled clutch cover and turned back wheels by hand with no spark plug in it, wouldn't pop out even as fast as I turned the wheels. Just want some ideas before I tear into it, also it worked fine before it seized up on me.

[yaegerb]

Don't know where you read most 200x gears do it. 3rd was the problem on all 200x due to the gear "dogs" not having enough meat to engage properly. If some transmission shims popped out I would say you either put them in wrong or missed one if it wasn't doing this before. Or, it might be time to replace that gear and the shifting forks. If you are patient enough you can find them all with time.

[Mickey Dunlap]

Never had one that second gear did this but it can have the same problem as any gear that slips out, bent shift fork keeping it from going into gear all the way, then you should be able to see the gear nubs rounded off. You will possibly need to replace the gear it's going into also, along with the 2nd gear and shift forks. I have no less the 6 gear boxes, less the 3rd gear I always need so if you need parts I have them. Also check the shift star for any rounding off or chips off any of the parts where the shift plate hits on the shift star. I am also out of those for the same reason, they are as big of a high wear item as 3rd gear.

233643

[DohcBikes]

If the trans worked fine before you took it apart, dropped some shims and reinstalled it I'm gonna take a long shot guess and say you did it wrong.