Need help form the engine building Kawasaki gurus

[Hoosier_Daddy]

I had a good running 1985 T3 engine. Problem is, the cases are junk. they have some cracks and welding. A long time ago I bought some cases in mint condition. I also bout seals to go with them. Well, needless to say, i am in a financial bad situation so I haven't dropped any money into it but I figure the least i could do it work on what I have to work with. I proceeded to take apart the old engins with the goog case halves a while back and just boxed up the stuff and set them aside. Tonight I decided to take apart my engine and swaap the cases. I have a manual that is an original Kawi service manual and was extremely surprised that they barely even touched this part of the repair. Well, I did get everything back together and i thought all was well. The crank does seem to turn harder then it did before. i figured this was due to the new seals. But, My main problem is, I can'r get the transmission to turn. I can't get it to shift gears either. mind you, this is while it's sitting on my bench. I can engage the clutch and it allows the crank to turn but the crank won't turn with out the cluch pulled.

Now it's obvious I put something in wrong i suppose. It is my first time breaking open cases and putting them back together but I swear, I put everything back the way it can out. Eben took pictures along the way to study and make sure. What could I have done wrong? Very frustrated. Don't have the money to pat someone else to do it right now but I have a feeling I'll be sitting on it for another year or teo just so I can get the funds to allow an expert to go through it for me. I love my Tecate and it's a great trike, but I have some much going on in my life that I'm starting to think it's more stress then what I want to deal with right now. I know most of you won't be able to help me be simply reading this post but i had to vent. I have been waiting 2 years to get this thing to a rideable, dependable state and i can't get around to it.

[fabiodriven]

Unfortunately, all you can do is take it apart and do it again. Good luck dude.

[DeePa]

you'll blame the honda but not the kawisaki????

[mudbogger]

When you installed the shift forks in the shifter housing did you make sure they were properly aligned? If you have a fork upside down, or not properly aligned in the shifter housing or on the shaft itself, it will not shift. Also, did you check the shift mechanism before installing into the cases, if that spring is not installed in the proper location it will not shift. Clutch pack as well, did you put the ball bearing in properly? I triple checked my shift forks and all the gears to make sure they meshed properly, took a period of time, but when done properly it will shift by hand easily, I would recommend splitting those cases again, that costs nothing, and look at the forks, gears. Did you take the gears off the splined shafts by chance?

[Hoosier_Daddy]

you'll blame the honda but not the kawisaki???? I blamed the Honda because I'm foolish and I was frustrated. Plus it was sarcasm. You understand that right? Turns out, the only thing wrong with that 350X was, it wasn't grounded well enough. Once i figured it out it ran like a top. That one was supposed to be the one my wife rode but financial hardships have forced me to sell it and my KX 125 too. The Tecate is all I have left and it's VERY slow going. I still have my pictures of the 350X and I really love the way it turned out. I miss having it.



When you installed the shift forks in the shifter housing did you make sure they were properly aligned? If you have a fork upside down, or not properly aligned in the shifter housing or on the shaft itself, it will not shift. Also, did you check the shift mechanism before installing into the cases, if that spring is not installed in the proper location it will not shift. Clutch pack as well, did you put the ball bearing in properly? I triple checked my shift forks and all the gears to make sure they meshed properly, took a period of time, but when done properly it will shift by hand easily, I would recommend splitting those cases again, that costs nothing, and look at the forks, gears. Did you take the gears off the splined shafts by chance?
Thanks for that advice. I'll split the cases and give it a look over. I have the original manual and it hardly shows jack squat about splitting cases and the pictures of where things go are terrible. I had to use my own digital camera to snap pics to see how things looked. I will split them again and check it out. Thank you for the tips and advice. I was given a generous offer from another member within driving distance that he would assemble it for me if I can't figure it out and that is very appreciated. Very appreciated. All I have to do is send it to him or maybe just drive and drop off. Cool gesture. I'd love to say who it is because he deserves kudos but i won't right now because i will respect his privacy as i don't know if he wants to remain anonymous about it.