jazzjourneyman
Member
- Jul 20, 2009
- 14
- 0
Greetings!
I installed a new stator in my 1998 KDX 220R, and it fired right up. This bike was purchased about a month ago, and started cutting out the day after I bought it. Unfortunately, shortly after taking off on a ride, the bike would only shift between first and second - and I could not get it into neutral. Then it got stuck in third - and finally it got stuck in a netherworld perma-neutral state - out of gear and moving the shift lever has no effect. It's not in true neutral - but maybe between twilight zone and outer limits.
Looking thru a borrowed Kaw shop manual [KDX 200 covering '95 thru -03], I am hoping that it is a simple problem involving the external shift mechanism, located under the right engine cover. Perhaps a broken spring, or worn/bent component. According to the Kaw manual, the right side cover has to be removed to check.
Has anyone had experience with a similar problem, and been "hands-on" with removing the right side engine cover and evaluating the external shift mechanism? FYI: the shift lever is not slipping on the shaft - and an oil leak has developed [I think] around the shift lever seal though that may not be relevant.
I REALLY don't want to have to pull the engine and split the cases - I think that would put me in over my head... if that's required, it might be better to part it out and buy a newer one... sheesh.
Any advice and shared experience will be greatly appreciated.
DT
I installed a new stator in my 1998 KDX 220R, and it fired right up. This bike was purchased about a month ago, and started cutting out the day after I bought it. Unfortunately, shortly after taking off on a ride, the bike would only shift between first and second - and I could not get it into neutral. Then it got stuck in third - and finally it got stuck in a netherworld perma-neutral state - out of gear and moving the shift lever has no effect. It's not in true neutral - but maybe between twilight zone and outer limits.
Looking thru a borrowed Kaw shop manual [KDX 200 covering '95 thru -03], I am hoping that it is a simple problem involving the external shift mechanism, located under the right engine cover. Perhaps a broken spring, or worn/bent component. According to the Kaw manual, the right side cover has to be removed to check.
Has anyone had experience with a similar problem, and been "hands-on" with removing the right side engine cover and evaluating the external shift mechanism? FYI: the shift lever is not slipping on the shaft - and an oil leak has developed [I think] around the shift lever seal though that may not be relevant.
I REALLY don't want to have to pull the engine and split the cases - I think that would put me in over my head... if that's required, it might be better to part it out and buy a newer one... sheesh.
Any advice and shared experience will be greatly appreciated.
DT
