I need expert only 200x help with motor PLEASE

[Solid Snake]

Ok, so here's the deal, bottom end is finally getting put back together. Kickstarter gears and a few gears on the transmission that connect to the kickstarter went out last summer. It's been apart ever since in our garage because I had to go back to school in Philly.

So anyways now I'm putting it together and I replaced the torn up gears from the 83 kicker and transmission with gears from the bottom end of an 84 engine that smoked blue and threw a cam chain a ways back, so it had a good bottom end though.

Ok, so I look in the Honda service book and some of the tranny gears changed to different teeth amounts and also the larger kicker gear changed teeth count. So I decide that I better replace all the ones that changed size from 83-84 with the good 84 ones which I had to do anyways because alot of the ones in it were bad. By the way my old post on this is here:

http://3wheelerworldforums.com/showthread.php?t=56478&highlight=bad+day+riding

I even talk about the teeth count change in my old post as you see.

SO.......I'm putting the case halves together and everything seems fine, --BUT-- I realize that the larger gear on the kickstarter shaft is rubbing heavily against the right case half inside, binding the kicker and stopping it from turning, and grinding my case inside.

So my question is, did the right case half for the 200x change slightly in that area from 83 to 84/85 to fit the larger gear, because the smaller gear would work but mine is ground up. Plus if I get one from an 83 kicker shaft, the tranny gears have to change as well meaning I would have to buy a complete transmission from an 83. The reason I don't want to use the 84 right case half is because I had all the gasket surfaces cleaned up and dewarped and also get new bearings pressed in.

PLEASE HELP ME AND GIVE ME YOUR KNOWLEDGE ON THIS, sorry about the damn caps but I'm pissed with this thing, took me forever to find out what was binding it. Thanks. I attached pics that should help explain what I'm talking about.

[kilabeez0]

can you compare the case half part numbers for the different years?

[Solid Snake]

I know one is an 83 (the one I'm using) and the other is an 84.

[Erics350x]

they are different 83 84 85 and of course the 86-87 all have different part numbers. your best bet is to use the 84 or grind some of the metal off.

[Solid Snake]

I figured it was the case, I'm definitely going to grind it down this weekend, seems like there is enough material there. I'll have to get some comparison pics or at least the pics of it after it's ground down just in case anyone in the future encounters this.

[BigRedBlair]

ouch..

fun with motors oh man

[Dirtcrasher]

They may have different part numbers, but I thought that the 83 thru 85 200X cases were identical. You think that they may have changed that housing just a bit to clear the larger gear?? Is it possible that something else is out of place or a shoulder on something is different from the years. A thrust washer in the wrong place or too thick?? Is something putting that gear towards the right or clutch side just a few thousandths to cause this??

[Solid Snake]

Nope nothing is missing, everything that went out went back in and I followed all the diagrams from the Honda Service manual and Clymer manual. It's more than a few thousandths of an inch. It's more like 1/8 inch or maybe 1/4 inch. I'll take pics tonight if I can.

[Solid Snake]

Well they are definitely different. You can see that all Honda did was grind down a section of the case to get the larger gear to fit in there. Threw in a pic of the garage just for fun.

[Levithan]

There was a fix in 85 for the kickstarter. Apparently that was a flaw of the 83-84 bikes, the gears would wear quickly, causing the kicker to slip every once in a while. I know that you can find the fix someplaces, I know a few people have had them here. Anyone here that can say more about the fix? Well, good luck man, that looks like a chore! If I were you, Id see If I could find an 84 case. I have one, but the crank bearings spun inside the case, ruining the area where the bearings sit.

[Solid Snake]

Well I have an 84 case as you see in the pics, ones an 83 and the other is an 84 with the ground down section. You can see I took a pic with one on top of the other to compare them. It definitely won't be hard to grind it but I gotta be real precise so I'm going to have the local shop either do that or just swap my new bearings into the 84 case.

[Erics350x]

i'd just swap bearings