KDX 200 H model tansmission problems

DonGood

Member
Jan 19, 2014
5
1
Hi all, I bought a KDX200 recently, bike was not running at the time. Got the motor running only to discover that the bike does not have gears above 3rd.
Yet when the bike is not running one can shift through all the gears???? Start her up and she flies off 1st,2nd and then 3rd and no more just nothing there. Opened and removed clutch to investigate, found that the shift shaft was bent, replaced it. Bike selects gears but makes grinding noise, kill switch ammediately. Tear cases apart dont know what im looking at. Took gears to a mech. says the dogs are worn on 4 of the gears? Now my question is can one undercut the gears so that they will engage??? Shift forks also look worn, replacing all 3. Any suggestions on under cutting?
 

ridejunky

Member
Dec 6, 2005
340
0
. Any suggestions on under cutting?

Yeah, dont do it, it may work for a while but there will be too much slop in the engagement, the bent forks are probably why it is grinding and not engaging, rounded dogs will cause it to jump out of gear, not fail to engage, unless they are so bad that it wont hold at all under load. see if you can find the parts or a used tranny online. BTW, that tranny was either abused or improperly shimmed.
 
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