I'm putting back together an 84 TRX200 that wasn't running. Someone had broken the gear shift pedal and then welded it back on, poorly. It had almost broken off again so I decided to replace the shaft and all. After I got the entire right crankcase apart so I could remove the spindle I realized why someone had just welded the pedal back on. Well, after reassembling everything I adjusted the clutch the way the manual says and everything appears okay. The problem is that it won't shift past 1st gear. It shifts fine into first and back into neutral. It doesn't matter whether it is in Hi, Lo, or reverse. Did I not get everything put back together right or is something else is wrong? By the way it shifted fine before I started. Any help would be greatly appreciated. I hate to tear the crankcase back apart just to see if it doesn't look right.

Thanks
Chris
cmorton@midsouth.rr.com

 

It sounds like maybe something was misplaced during re-assembly. Maybe a shift fork. If it shifted fine before tearing the motor down, it would have to be something not put back together right. I know the feeling quite well.

 

ever hear someone say, "if it aint broke, don't fix it"..............I don't mean to be a smart ***, but this is a perfect example of what that means.

why did you want to replace the whole shaft if only the foot pedal had been welded? just curious.

 

Had no choice, the weld job was so bad there wasn't enough of the shaft left to weld it back to after it broke off. The pedal was already rubbing the recoil starter due to where they welded it. It looked like the original break had been the end of the shaft. Must of been a pretty hard hit.

 

cmorton,
i am sorry.........i misunderstood your first post to say that the shifter was broken, welded and about to break again.........so you decided to replace the shaft & all.

since the shaft & the shifter are 2 seperate parts which can be unbolted from each other, I couldn't understand why you would want to replace the shaft due to a broken shifter.

what you are saying is that the shaft was broken. I get it now