shifting problems

[mikeps3]

Hi every one i just got a 1991 kdx 200 kawasaki and i took it for a ride today went about 30 miles every thing was fine then i went to down shift and i could not get first gear kept going into netral got home let it set for awhile tried again to change gears and i was able to get it into first gear but when i would take off it would pop into neutral every time i could ride in second and take it to top gear but it won't stay in first gear it was a little low on tranny fluid but i got the level back where it should be but still won't stay in gear . any ideas what it might be thanks

[sandblaster]

Hello and welcome to the forum.
I saw this same question you posted at forum X  and I know from past experience that you don't get a lot of response there.
It's always hard to diagnose these kinds of problems based on descriptions.
However, if it was me, I would remove the inner and outer clutch cover and take a look at the shift cam asy.
Look for anything that is out of place or clearly worn.
Have someone rock the bike gently and shift the gears while you watch the mechanism and see if you can see something.
If that does not pan out your down to splitting your cases and looking for broken snap rings on the transmission shafts, worn or broke dog ears on the gears, worn or bent shift forks, worn, shift drum.
Do you have a Service manual for your bike?
If not, it would be a good idea to get one before you start tearing into things
Keep us informed and post pics as it really helps us see what you have going on.

[mikeps3]

thanks i will give that a try, its just the bike was runnig real good and just bam it started having shifter problems no warning and i was taking it easy on the bike

[mikeps3]

i was trying to find a pic of a shift cam asy but can't find one anywhere i was at bike bandit and was looking at a view of the tranny but no mention of a shift cam asy part?

[sandblaster]

Sorry for the description of shift cam asy.

Look at 13091 and 115


And 13236, 132, 92143



Like I say, I don't think this is where the problem is but it's worth a look as it's easy to fix..

[superman]

Try using some FORD ATF  transmission oil. Heard of the same problem before and this works well.

[mikeps3]

we split the crank and under the transmission gears we found a small piece of metal about the size of a ballpoint pen clicker ,it was magnetized and sticking to the gears ,don't know where it came from but every thing looked fine so we put it back together and it shifted just fine, also if anyone wants to know a 2000 kdx 200 motor will bolt into a 1991 kdx 200 frame just have to make a motor bracket for the top ,i know it will work because we did, it works fine, i guess the guy i bought the motor from must have got that metal piece in the tranny when he rebuilt it

[sandblaster]

It looks like the magnet from a magnetic drain plug.

[Goat]

It looks like the magnet from a magnetic drain plug.

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