83 XR200 Clutch/Tranny Problem

EatnDirt · Jul 17, 2005

I've run into a strange problem with an 83 xr200. The bike was running just fine, clutch working normally. My gal stopped the bike in gear, holding the clutch in and idling. Less than half a minute later she lets out the clutch and nothing. The engine just revs, acts just like it's in neutral. Closer look shows that when the bike is in gear and the clutch is released, the chain jumps a little as you rev the engine.

My first thought was the clutch wasn't disengaging. I checked the cable slack and everything is ok there. Next step was to remove the clutch. Once I got the side case off I discover a special tool is needed. But in the meantime I removed the 4 screws holding the clutch plates in to take the pressure off the clutch plates.

With the bike on the stand and in gear, should the clutch basket turn when the rear wheel is turned? The clutch is fully released (I took the small plate and clutch springs out).

If it's not the clutch, my only guess now is something in the transmission isn't fully engaged anymore.

Has anyone run into this type or problem before?

nickyd · Jul 18, 2005

its the clutch. that is the symptom when the plates are worn (they don't engage and the bike acts like its in neutral) - you only need the special tool to pull the basket (which you won't need to do to replace the plates) - pull the plates off and measure the thickness(the fiber plates) with a micrometer or caliper - check them against factory specs. check the steel plates to make sure they are flat (not warped - you can lay them on a piece of glass and try to insert a feeler gauge underneath them - again, compare to factory specs) - lastly - check the basket "fingers" - where the plates slide into - make sure there are not deep grooves in them fingers (from the plates hitting them) - this can cause the plates to hang up. if there are deep grooves you can gently file them down - you usually can do this one time, sometimes twice before the basket has to be replaced.

Trailhog · Jul 18, 2005

My friend had an '83 XR 200 that done the same thing, the counter shaft had stripped and would just spin inside the front sprocket. If the front sprocket was ever replaced more than likely the stock retaining clip was chunked and a AM clip was used which means there was alot of play there. Could be your problem.

EatnDirt · Jul 18, 2005

Hmm. I take another look and see if I can pull the plate out without taking the oil filter rotor off. I thought I had tried but I'll give it another shot before getting the tool.

The only reason I thought it might not be the clutch was the fact that it worked perfectly up til the point it quit working altogether. On my CR I can feel the clutch wearing as I'm riding.

Trailhog: I'll check the front sprocket area too.

Thanks for the tips!

EatnDirt · Jul 18, 2005

Just to update. Checked the drive sprocket and sure enough, the teeth on the inside of the sprocket that grip the shaft striped out. It needed a chain/sprocket replacement anyway. Since i have it apart this far though, I'm going to put a new clutch in.

Thanks for the help!

nickyd · Jul 18, 2005

what stripped - the shaft or the sprocket? I guess I need to be reminded to check the easy stuff first!!!

EatnDirt · Dec 5, 2005

nickyd said:
what stripped - the shaft or the sprocket? I guess I need to be reminded to check the easy stuff first!!!

Sorry haven't checked this thread in a while. The sprocket itself stripped out. Teeth on the shaft look like new.

83 XR200 Clutch/Tranny Problem

EatnDirt

nickyd

Trailhog

EatnDirt

EatnDirt

nickyd

EatnDirt

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