That explains it. You'll need to get a special tool to remove the centrifugal pickup (which is just above the clutch in your pic, secured with three Phillips screws) and the clutch. This tool will remove both parts for you: http://www.ebay.com/itm/Honda-Motorc...909af6&vxp=mtr

When you remove the cover from the centrifugal pickup, you'll likely find some silver sludge inside. Make sure you clean it all out. It's a good idea to replace the gasket that is under the cover as well. If you have access to an impact wrench, it will make removal of the three Phillips screws much easier. They strip easily.

When installing the bolts that worked loose, clean them well and secure them with blue Loctite 242 or red Loctite 262. Use 242 on the Phillips screws.

I already had phillips screws out how I found out needed special tool and clutch is held in place with snap ring thanx for link now I know what gotta get

The bolt on bottom is screwed into case my question is what goes into hole on right

Not sure. It looks like there are two available points for the shifter detent, which is the item at the bottom of your case. It has a spring-loaded roller that applies pressure to the shifter star, and that's what you feel when you shift gears. When you remove the clutch, shifter detent and shifter star, it should all be clear. If not, let us know, and I'll remove a cover on a spare engine I have.

Ok thanx I just ordered tool some I can take that piece off so can then take clutch off then I can tighten and loc tite everything. I also got some blue gasket maker and bought blue and red loc tite

What is shifter star suppose to look ln first just in case its outta wack

Any idea where I can get an engine manual for this and I also found out they had two versions of the 163fml

Don't worry about the placement of the shifter star, since it has a small hole on the back that engages with a pin. It only goes on one way.

Your engine is identical to the CG125, which was very popular in Brazil and the UK; there is a ton of info for it online.

Awesome thanks found an engine repair manual for the cg125 and its extremely similar to the 200 I'm hopfully gonna tackle this this weekend if I get tool and if the weathers "warm" enough

Got tool today and tightened bolt I'm hoping that's what problem was leaving it empty overnight to let silicone cure. The shifting star wasn't even on the pin on shifting shaft ill see how it goes tomorrow after fill it back up with oil.

It sounds like you fixed the problem. :tup: You can safely test your repair by rolling the bike and trying to shift the transmission before you replace the crankcase cover and refill the engine oil. ;)

Just did it already had cover on don't know why didn't try it before did cover. I noticed when was tightening lock nut on crank that the bike was moving while I did it so I assumed it was working. Ill find out tomorrow though fingers crossed

Got her drivin again and for a 200cc it moves me pretty good (I'm 6'4" and 240lb). Found some things I wanna improve upon like a bigger stiffer rear shock and drain and fill forks as there lil too soft for me. All in all no complaints. .......yet

Excellent!

Can you move the lock nuts on the shock, to apply more pressure to the spring?

I have had good experience with using the fork oil that Spud recommends, which is Valvoline Max Life Dex / Merc. Good stuff.

I haven't tried lock nuts yet and want a taller seat height also but I've read spudes yhread bout the front shocks couple of times I'm just waiting for warmer weather as its cold in nh