85 200x gears stuck when tightening cases

[chasemanmusic]

Hey guys. In the process of assembling my 200x motor. Replaced the bearings in the case. Cleaned and dried parts. Assembly lubed moving parts. Meshed gears of main and counter shaft (pretty sure they are correct), installed shift forks and shaft. Able to spin shafts by hand and manually shift shift drum. Put left hand case on. Goes on without issue, shafts still move. after I tighten the cases down hand tight I can't move the shafts. They are stuck.

Obviously something isn't right with my assembly, but I've triple checked the gears with the pics in the manual and I think it's right. Plus I thought the cases wouldn't meet nice if they were assembled wrong.

Any tips or advice from experience would be greatly appreciated.

Thank you,
Chase

[barnett468]

Replaced the bearings in the case.

it the bearings are chinese, they might be a hair too wide, otherwise you might not have gotten them in all the way to the seat . . they shafts only hafe a few thou of end play so it tales very little to be off to cause them to bind . . i would check to see if they are seated all the way..

[oscarmayer]

I would say you mis-assembled the bottom end and a thicker spacer was used in the wrong spot. Other thing you may not have properly seated the bearings.


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[chasemanmusic]

I opened it up and I'm thinking the bearing are not seated all the way. The left case bearings are not flush w the case material. Going to bake the case and try to tap them in all the way.

[atc007]

If you didn't use a center gasket. That is your problem. the thickness of that gasket is imperative on these. If you did, whatever's not right won't be too hard to find :)

[chasemanmusic]

I did use a center gasket and I wasn't able to get the bearings in any more. I confirmed the drive shaft bearing all the way in the the main shaft bearing ( the one recessed or hidden in the case) I can't tell. It does not sit flush w the case but I'm not sure if it's supposed to.

[oscarmayer]

Put the assembly into the oven and heat oven to 300*
When it reaches 200-220 take the assemble out and tap the bearings flush. Not sure why everyone is always hell bent on. Installing bearings cold but that is the fastest way to jack a case up. Use heat and it drops in like butter.


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[chasemanmusic]

Got the cases assembled properly now. 2 things I did differently. Found one gear that I think was upside down, not sure if that mattered. And I followed the Honda manual assembly procedure rather than ththe clymer one. Honda said to populate left case rather than right and also while the cases are going together to twist the kicker shaft. When I did that it like clicked and everything fell into place. I could tell immediately.

Thanks again for the help everyone.