Ok finally brought my 200e back to life the other day. (Has been sitting with blown head gasket for months now). I changed the head gasket and while I was at it I had a new set of clutches just laying around (was gonna put em in the 185 but I decided it was beyond repair) so I put them in while I had the engine out. Now the machine has times it just will not shift (seems like I remember it doing this the one time I rode it before I submarined it but that's been a while).

What I mean is just at random times it will not shift into the gear I want. Say I'm trying to go from 2nd to 3rd. I press the pedal down and when it reaches the point where it should shift it feels like it hits something solid (much like the feeling when you try to upshift when you are already in 5th)and will not shift. If I kick it back to 1st then go through second it will go into 3rd. Then it may work right for the next 40-50 shifts and then it will pick another gear say it wont shift down from 2nd to 1st (I know both examples used 2nd but it isn't tied to any gear the only thing it hasn't done so far is hang in 5th) so kick it to third then it will go back down. Its absolute favorite gear to not shift into is neutral.

Any ideas?

 

You might need to adjust the clutches. There is a nut with a screw in the middle of it close to the oil dipstick on the RH side of the engine crankcase. Loosen the the nut then adjust the screw. I'm not sure which way you need to turn it but there should be a fair amount of slack when you wiggle the shifter up & down before it clunks into the next gear. Just don't make it too loose or it will slip.

I found this guy very helpful: