KDX200 Shifter & KIPS Pin Repair Part:2 of 5

The larger clutch side case cover is removed with the discovery of the KIPS governor lever pin broken off. Fragments of this broken part were found resting at the bottom of the clutch side case, however not all of that part was found, namely the actual lever / pin. Also there was debris hindering the shifter pawl mechanism from engaging the shifter drum turret and once cleaned up, now works fine.
Lastly, there's the issue of the shifter drum turret which does not seem to shift smoothly between gears, as if 'something' is binding it up intermittently.
Please comment to the KDXRIDER.NET forum link below.
www.kdxrider.ne...

[@themasseys439]

Thank you for these great videos. I am getting ready to tear apart my 94 kdx200

[@BluuSkyz]

Thank god for this video.. I snapped my pin I believe from the actuator while changing top end.. I'll use this video to take side off tomorrow.

[@jamielukas100]

thanks for the video.really helped

[@tylermatthews4525]

Just after 3 minutes into the video, when you had a washer come out around the right side of the motor, where did that washer go? I used these videos (great videos!) to pull my 220 motor apart but I cannot figure out where and how that washer fits back in around that area.

[@silviowanderleimaieski]

Muito bom o vídeo mas não entendo o idioma inglês infelizmente. Mas ajudou muito. Congratulations!!!

[@Bark3rd]

I have been wrestling with re-installation of the gear change assembly on my 85 200A (air cooled but the shift mechanism looks almost identical). When I slide it in and attach the shifter on the other side, shifting the gears with my hand to make sure everything works correctly I get a few issues: 1) can only upshift and downshift 2 gears- should I be able to work all of the gears? 2) I'm having the exact same issue with the little spring not pushing the teeth far enough forward to fully engage the turret, I think its a matter of assembly and how the bushing behind the rear plate engages into the hole between the 2 plates. Or, the spring is stretched out? 3) after shifting a few times the mechanism plates separate and the parts come apart. Is the only thing holding the plates together that little spring? 3) how do you know the turret is in the right position before buttoning everything up? I'm worried I will assemble it with the teeth in the wrong starting position on the turret. Also, how do you keep the shaft in place when installing the clutch cover, the shaft wants to pop out a few CM, do you have to pull on the shift lever to keep it out during assemblt? Any advice would be appreciated!

[@Catfish2255]

You have to move the rear tire enough to move the tranny gears to let everything slip into place..it won't just shift all 5 gears sitting.

[@brianheggie8503]

Can the shifter shaft be fully removed through the right side of the engine?

[@alaskadroneshots1057]

Brian Heggie yes it can be.

[@TheTruthMatters]

When's the last time you cleaned your kips exhaust moving parts?

[@lewismichael1988]

is is possible the fragment came out during a routine oil change?