What kind of gear box problems have you seen??

[Dirtcrasher]

I just split a case on a 250SX - lots of moving parts - it made noise in nuetral and and didn't do anything in first. To my surprise all the gears teeth are good and forks look straight. All the locking springs etc. all looked good. All I found was some of the engagement tips - where one gear drives another - had slightly rounded corners. However the shift cam had some worn high spots in it. One looked like it always rubbed - maybe the noise in nuetral.
This engine had never been split and all bearings and journals were nice like it always had oil in it.
Unless I see a broken or damaged part I'm not sure of the cause. Al though it's stock could additional shims be necessary or something. I'll get a new shift cam but I need some insight from you gearheads.


Just curious what some of you have seen or dealt with and how you went about fixing it. I'll try to post pics later. Thanks

[ATCs Reborn]

not sure what to tell ya on the noise in neautral except to make sure you check all your bearings well before puttin it back together.
what i can tell ya is the rounded lockin pieces that you mentioned is why you have no first gear. these are very precision pieces and any that aren't squared off should be replaced so ya don't have to pull it apart again after 20 hours of ride time.
good luck,
steve

[Dirtcrasher]

The bearings and shaft journals are excellant. I'm just curious what others have run into during teardown and repair. The wose wear is on 2 high spots on the shift drum. Some gear nubs are slightly rounded.

[Dirtcrasher]

I'm the only one who's ever worked on the transmission?? Help

[Dirtcrasher]

So, uuuuuhhhmm - noone fixes transmissions this themselves.

Stories, problems, solutions etc. help

[thefox]

Check to see if the shaft that the shifter forks are on. I had a yamaha 200 that had one sligtly and that caused it to be stuck in gear. When I fixed it I put the forks on wrong, turns out they a numbered for a reason :oops: . So check to see if the forks are good. When I put it together wrong it would grind in first gear.
hope this helps,
Andrew

[plkmonster2]

yeah, make sure all the forks are straight, and that they aren't extremely rounded. look for things in the gears.

[LaDano]

Dirtcrasher, I'm in the same boat but with a bayou 220. I guess I'm gonna bring it a shop, which is against my will. Good luck Dan