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Thread: 200x kickstart gear replacement

  1. 02-21-2015, 09:21 PM #1
    jonny23's Avatar
    jonny23
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    200x kickstart gear replacement

    Has anybody ever replaced the kickstart gear on a 200x? If so what does it take and how hard is it?
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  2. 02-21-2015, 09:29 PM #2
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    ironchop
    ironchop is offline Power User The day begins with 3WW
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    Yes....but you have to split the cases.

    I had a manual and took cell pics while I was disassembling it so I had a reference point to reassemble without any confusion.
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  3. 02-21-2015, 11:55 PM #3
    YTZ drew
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    You will need a full engine gasket kit and a special socket to get the clutch and the "oil filter" (as Honda considers it) off. Also, you probably will need an impact driver for a few phillips screws that are actually a "JIS screw" and tight as heck. Be careful sourcing parts, 83, 84, and 85 are all different. Make sure the gears you get match what belongs in the engine.

    And my last recommendation: get a 185/200S/XR cylinder head and swap it for the stock one so you'll gain a compression release. That may be what saves your next set of gears! The heads are identical other than the compression release and the shape of the bottom 2 fins.
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  4. 02-22-2015, 12:55 AM #4
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    yaegerb
    yaegerb is offline yaegerb The day begins with 3WW
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    It takes a good manual (clymer sucks....trust me), oil slinger socket (special) tool, a penny, case splitter tool, complete gasket set (recommend Versah), an NOS ratchet/spring/gear (not used....again, trust me) and a sprinkle of patience.
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  5. 02-22-2015, 10:47 AM #5
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    A Haynes manual is not bad. Cometic also make good gaskets.
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  6. 02-22-2015, 11:38 AM #6
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    Sounds like a serious job, looking at an 85 but kicker slips,
    What parts would I buy? Just the gear or are there more I should get while there.
    Last edited by jonny23; 02-22-2015 at 12:21 PM.
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  7. 02-22-2015, 01:02 PM #7
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    yaegerb
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    http://www.servicehonda.com/parts/lo...HA2FHA28E1000B

    You need 7, 3, 4, and 1
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  8. 02-22-2015, 02:29 PM #8
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    i can leave everything else if it's good? I'm guessing eBay is my friend on parts since there not available through Honda?
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  9. 02-22-2015, 03:13 PM #9
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    Dirtcrasher
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    Yep, I had 3 kits a few weeks back to repair these issues.

    85 Is just a spring
    84 May be 2 gears and countershaft low gear.
    83 Is 2 gears and a spring.

    These kits are hard to find and I sold all near immediately offering them for sale. I'd prefer the Honda repair versus stretching a spring and back cutting the gears but thats some guys only possible fix.....

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  10. 02-22-2015, 04:47 PM #10
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    jonny23 is offline At The Back Of The Pack Arm chair racerFirst time rider
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    85 is just a spring? Mines an 85. This is all new to me. I plan on buying service manual soon
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  11. 02-22-2015, 05:05 PM #11
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    I have a couple kits in stock and if the kicker is slipping you will need both ratchet gears and a new heavy duty spring .
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  12. 02-22-2015, 05:24 PM #12
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  13. 02-22-2015, 05:28 PM #13
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    jonny23 is offline At The Back Of The Pack Arm chair racerFirst time rider
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    What is a good service manual to get? Original Honda good?
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  14. 02-22-2015, 07:19 PM #14
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    Honda OEM service manual is best
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  15. 02-23-2015, 09:16 AM #15
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    Does that xr head swap work on the 86-87 200x?
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