Side gear case ATC250SX...HELP!

[ATCSX]

today i was helping my father in law work on his 85 ATC250SX (really moreso assessing the damage) and during it all (tore down the rear end, all bearings shot) he ended up pulling the side gear case...now we can't get it back in. we can get it almost splined in but can't get it all the way...can someone please point me toward the light? i'd be grateful...

[atc500x]

Hummm....if you have chance,it's only the idler gear between the kickstarter gear/shaft and the clutch that wont go on the shaft.....but I'm pretty sure you wil have to split the case completly to reinstall all the gears....You have probably just remove the 3 bolt and pull the shaft.....big mistake....

[oscarmayer]

that little pull will cost you dearly.
in ym sig is a link to a honda manual for the 250sx. read how to do it.

[Dirtcrasher]

I gave an entire tutorial as to how to fix this.

It requires lining up the oil holes with the collars,laying it on the side and getting access to everything from behind the kicker gear assembly.

All you need to remove is the clutch cover and kicker gears and MAKE SURE YOU FIND EVERY PART, esp. the dreaded "thrust washer".

Good luck finding my tutorial, but it was for a guy just like you in your situation..... I just hate repeating it every 6 months, it ought o be an SX "Sticky".

Leave out that washer and 1st gear goes bye bye real soon :)

But, all and all, it's a PIECE OF CAKE :D

[Dirtcrasher]

I just realized your a new member and Fabiodriven busted my chops and asked me to "help the guy" - SEE, Fabio isn't a bad dude at all!! :D Plus, I can't find my "tutorial post" so I'll do it just for you :beer Maybe Karma will come my way!!

You made the mistake many others have done. It's not hard to fix unless your creative (thats how I figured it out) or lucky or you get it together but incorrectly and then usually it gets sold..............

If you DO find that other post, it may have even more helpful info........

Anyhow, start with it upright and get all the parts out. Now remove the kicker cover and the kicker gear assembly. Now you can get in there with a flashlite and a magnet to get out that thrust washer. Some guys can get them back together, but don't get that washer in place and it's very CRITICAL!

Flush it out with some gas or diesel if you have to, but make sure there aren't any other collars/clips or washers left in there. Flushing it allows the stuff that fell off to be found jiggling around and a magnet and flkashlite get them all back to you :D

Now lay it on the side perfectly flat, no angle at all and use wood or otherwise to do this.

Now place that 1st gear thrust washer in 1st, use grease to hold it in place. Start placing in all the gears and there collars. Just remember that if a collar has an oil hole, it MUST line up with either the gear or shaft oil hole too.

I cannot explain to you which gear goes where, refer to the manual for that. And collars, clips or whatever - again, just refer to the manual. If you don't have a manual or don't download a free one, good luck and I don't like going way out of my way to help people that won't at least attempt to read and use the Honda bibles............

I don't think many or any of the gears actually stay in place on the ES countershaft which makes this more difficult. Honda LOVES when guys pull those 3 bolts!!

Now just merely slide the shaft back in while you rotate the right angle shaft just a bit. If it doesn't go in smooth, STOP!!!!!!!!!!!!!!!! Something is incorrect, out of order, backwards and or binding........

Post up any other questions.

Follow the book and those instructions and your golden, ENJOY!!

LOVE,
DC

PS - If you were in a hurry and already got the shaft back in, 99% of the time that thrust washer is overlooked si be sure check it, find it and get it in it's place :D

And Oscar telling you the case has to be spilit is an assumption MOST of us would make, so no harm there. The SX/ES motors have like 1000 pieces, I hate spliting them!!