2004 RM250 gear shifting assembly questions
- Thread starter pokemanyz
- Start date
pokemanyz said:
1.How do you install#9 without turning #7 & #21?
(that seems to be causing an issue)
2.If #11 & #12 were reversed would that likely cause dropped shifts, popping out of gear?
2004 RM 250 :ride:
I would tighten that bolt with the transmission in first gear.. Then the shift drum should not move.
As for the pawls being installed wrong, yes that could cause the trans to come out of gear.
Its usually not a lot of torque on the bolt, blue loctite and a lock washer?.
- Thread starter
- #6
Update
You can't install #11 & #12 the wrong way & still be able to shift. (I tried real hard)
When I looked at the manual it shows it wrong & so I thought that was where the shifting problem lay. Look at page 8-3 of the Suzuki manual, it clearly shows the pawl with the wide part of the slot facing the wrong direction.
So I thought I had discovered the reason for the shifting troubles.
Now I'm leaning toward the shifter was mounted too high & I was getting incomplete shifts. I took an engine a part that never had a shifting issue & now it has some serious issues.
You can't install #11 & #12 the wrong way & still be able to shift. (I tried real hard)
When I looked at the manual it shows it wrong & so I thought that was where the shifting problem lay. Look at page 8-3 of the Suzuki manual, it clearly shows the pawl with the wide part of the slot facing the wrong direction.
So I thought I had discovered the reason for the shifting troubles.
Now I'm leaning toward the shifter was mounted too high & I was getting incomplete shifts. I took an engine a part that never had a shifting issue & now it has some serious issues.
Last edited:
Shift fork #3? It does appear its depicted wrong, but the fork will engage the drum only 1 way. Is the trans properly timed; are the shift shaft, shift star and drum all set in neutral? And is #11 installed the correct way? Then that leaves 20/20a to be installed correctly? The shift lever to high, is sort of possible?
- Thread starter
- #8
whenfoxforks-ruled said:
It shifts great during all stages of assembly. Everything spins & moves just as it should. Right now I just putting the outer clutch cover on. I can put the shifter on & it'll shift just fine. It did all this before though.
I even ran it up & down the the street & it shifted just fine through all gears. I'm putting it all together again & will test it out.
