tranny rebuild disaster

[ytguy]

I recently bought a set of cases and a box of tranny parts from the fox for my ytm 200. I just finished puting the motor back together and mounting in the bike tonight and ended up with exactly what I started with. I can't get in neutral and if i start it and let the shift lever out it moves about 20 ft and then sounds like a bag of marbles in the tranny. I checked, rechecked, and checked again every step of the way. Anyone got any ideas? :wondering

[hrc85250r]

spent bearings, missing spacers/washers....did you go by a manual or what? did you check schematics to make sure you had everything?

[ytguy]

I used a clymer manual, and checked every schematic extensively. Shift forks warped? Or the shaft they ride on? Or how about the shift drum? Everything looked good, no wear matks but how do you know?

[rustbucket]

I bet your missing a shim somewhere or its in the wrong place.

[350x'inNY]

I bet your missing a shim somewhere or its in the wrong place.

I know I was looking at the Yamaha Factory Repair manual and they had pages and pages of different shims for different numbers on the shafts, etc. My Yamahauler I got form Holic has something in the SubTranney amiss, and I'm not looking forward to tearing it apart and messing with the shims and crap. Luckily I have a couple spare lowers around...ones a 225DR one, and looking in my Clymer and Factory manuals, the subtranney/reverse looks the same.

Bruce

[jenndnn3]

Your tranny's are not that bad, I swear. Go to a schematic and print the full page on it. Their price list as well because you will reference it. Partsfish, bikebandit, whichever your fancy. On the honda's they list teethnumbers, locking cclips, thrust washers and whatnots. The schematics give you the inside width of the washers you are to use via mm. If your gonna split I highly recommend a micrometer to measure so you dont mix them up! Kinda hard because different area's of the shafts are different sizes. Just systematicacly go through each piece, adding that as called for on the schematics. I have alot of trouble useing the manuals, they only describe each gear, when it comes to this so I just use the schematics. Just remember almost every piece is different, as long as you follow it you should be fine. Oh yeah pay careful attention to the directions the sprockets line up. With that being said fingers crossed as I fire mine up this weekend.... :eek: