needing 250sx pro

[jsizemore]

here's the deal. i own a 1985 honda 250sx. the swingarm bearings went out so i started out on changing them. while in the process of removing the driveshaft i removed the output shaft from the engine also. when i did so you could look into the block and see the gears just loosely sitting there. now im usually a decent shadetree but i think i screwed up bad here. i guess that will happen from time to time. any advice on how to install my output shaft or if i even can without dis-assembling the engine. any and all advice is very apreciated

[Hurricane635]

It's not impossible, all the gears go on ok with a little wiggling and shaking. But there is one shim on the end inside the cases that will fall out of place. I think I saw a thread on it a while back that talks about washing the cases out and picking up the shim with a magnet. Good luck.

[jsizemore]

any idea on where to get a picture schematic of where the shim fits?

[Hurricane635]

Look in the world class help, the shim goes against the inside case behind the clutch.

[Tri-ZNate]

http://www.bikebandit.com/houseofmotorcycles/1985-honda-atc250sx/o/m1913#sch8794 there is every schematic you need

[250Eddie]

Wait u can see inside the tranny from where the drive shaft goes connected???
If so the seal that goes there is gone for good lol, u might have to clean trailprotrailpro tranny out and put new oil and the new seal.

[TheRealFatShady]

YES you can do it.

Seemed daunting at first, as my 'friend' took out my output shaft and lost that thrust washer in the tranny (and then slammed the engine cracking my case....but that's another story), but I got it out.

Quite simple, actually.

Go to Harbor Freight and buy a snake magnet with LED light on the end for like $7. Put it in the big hole where shaft came out of. Use the light and magnet to get the washer. I used tape to hold the washer in place to get it back to where it needed to be, that was probably the harder part.

The shaft can get all gears to fit back on by wiggling, I used a pipe (I think 3/4" diameter???) to help align them. Got it all back in perfectly and all gears work, plus that important thrust washer is in it's place.

You'll likely need to take the side cover and clutch off on the right side of motor, where the oil feed hits the end of the output shaft. That's where that washer fits.