having trouble with crankcase cover (HELP)

[MudBug]

when putting the right side crankcase cover back on my big red 250 i'm having problems. it can slide on halfway and even so the bolt holes are not lining up. Im thing the reverse lever thingy is hooking on something and stopping it from going in. I was thinking about taking that reverse lever and spring off the case and putting it in the motor and THEN put the cover on. should I do this? any suggestions are appreciated :TrikesOwn

[Honda_Dude]

Yes, that is really how you are supposed to do it. It will go MUCH easier if you do it that way. I just did this on a 250sx a couple of weeks ago.

[MudBug]

im not exactly sure how to get it apart? its been really stiff so far. but thanks I will keep trying

[Dirtcrasher]

I disagree, it goes right on if you use the outside lever and turn it while popping the cover into place.

Whats stiff?? does the whole arm move smooth?? That outside arm I believe is just bolted onto the shaft with an 8 or 10MM bolt and it's onto either a splined or square male machined into that shaft. EDIT - It's on a taper...... I still wouldn't remove the arm and I think your overlooking something..........

It's honestly harder for most people to re align the outside arm and possibly damage the oil seal by removing it.

Take a good look at it, think about what it does. The cable pulls it away from the shift drum so reverse can't be engaged. If you don't move it enough or too far, the arm will hit something else. This is of course that your not overlooking something else that may be preventing it from going on smooth.....

The more parts you can keep together, the better...... It isn't necessary to remove that arm from the case. The only reason to remove that arm is to assemble the cover to ensure that nothing else is binding when popping the cover back on. Sometimes the kickstart shaft tends to make aligning the cover a bit harder as it springs in one direction without the support of the outer case. And of course the dowel pins need to be clean and grease them up and the cavity they go into......

[MudBug]

ok thanks DC ill try rotating it a bit again. but usually the spring falls off the lever

[Dirtcrasher]

The spring is the "return spring" so if you rotate the lever just like the cable does, there should be tension on that spring - no??

And don't forget, if there is a thrust washer on that shaft inside the case, just grease the hell out of it to keep it in place while assembling...

Little obstacles like this are what make you a better mechanic and give you a clearer idea of how things work.

I honestly get PISSED when stuff won't go together, BUT, I love when I can see exactly what the issue was. Then I think to myself (you idiot, that was chicken) and I learn from it and share it with you guys.

I have my 85 250ES motor downstairs so if I need to do a dry run for you on assembling that right cover with the arm in place I can do so. I just poipped the arm off an hour ago so I could see if it was a spline, a square or what I found - a taper. Just for you buddie :D

GLUCK!!

[Honda_Dude]

Well DC has obviously been through this way more than I have. I had the same issue you did and taking it off first seemed to work for me. Good Luck !

[MudBug]

wow DC thanks alot man im going to try it again after. where does the other side of the return spring hook? thats basically all I cant understand at the moment