Motorcycle Repair: 1997 honda xr200r, clutch action, clutch springs

Question
I just purchased a used 1997 xr200r 4-stroke. I was told that the bike will shift up through the gears but will not downshift without pulling outward on the shift lever. It is also nearly impossible to get it into neutral. The clutch lever is also very hard to pull back whil it is connected to the engine. HELP

Answer
Chris, First of all, you need to find out why the clutch pull is so difficult. It shouldn't be like that on any Honda, unless someone put racing clutch springs in it. Loosen up the cable adjusters and undo the clutch lever from the bracket, then check the cable for free and easy movement in both directions. Replace the cable if in doubt and make sure that it is routed properly, so it isn't up against the fuel tank, pinched against something or melting against the exhaust pipe.

Once the cable is squared away, check the clutch action again. If still too tight, then check the clutch release lever. To do this, you will need to drain the oil and then remove the clutch cover. The release arm is mounted in the cover http://www.cmsnl.com/honda-xr200r-97-us_model7740/partslist/E++07.html  Plan ahead and get a gasket and any seals for that side, before you pull the cover.

While the cover is off, you can check the clutch assembly and the end of the gear selection drum/shift shaft for damage or loose parts in there.

You can always upshift with no clutch on most engines, but downshifting is more difficult and the clutch is recommended. It really sounds like the clutch is bound up or the cable is frozen or something is happening to keep the clutch from releasing properly. You will have to dissect it until you find the reason.

Bill Silver