'83 250R transmission questions

[Gdkarma]

Can anyone point me to some good drawings of the transmission assembly? I want to go over everything and figure out what is wrong with mine. Took it apart yesterday, and I don't see anything obvious that would make 3rd gear not work. Forks look good, drum looks good, no worn gears, nothing looks out of place. So, I got to thinking maybe someone has been in this transmission before, and didn't get something assembled correctly. Before tear down, when it was shifted into 3rd gear, it was like nothing was there. I would hate to take this to someone and pay them to figure it out, since I have gotten this far!

[jenndnn3]

look at bikebandit.com or partsfish.com. Tho I will tell you right now, On my 87 xr200r the schemes showed one way, and the gear actually went the other way. That does not mean yours will be the same.

I used one of those plus the manual. Those give every piece. Without each gears name (first second on and on), but give number of teeth, Manual just names the gears.

[Gdkarma]

Thanks for the help. I have gone to both sites, they have the same information it seems. I printed off the diagrams, and am trying to also use the manual. Just seems odd that nothing sticks out as a problem thus far. I will keep going this route, until someone has a better option.

[jenndnn3]

Take the 2 shafts, put it all together, lay it out, if you possibly can together kinda floating in the air so you can freewheel the gears. as you are turning them, use a shift fork to shift the gears. You will see if there is any problem at all in the tranny. If a gear is in backwards or not. I did that, and thats how I figured out one of my gears was backwards. The gears do sorta make it obvious what goes where, but there was one (i think it was third and 4th as a matter of fact) that is not so obvious. I couldnt float mine, so I used a case and fought it that way. I have small hands so it worked. You may try it that way as well.

Another thing to try is to put it back together in case, with the drum, forks and star for leverage, leaving right case off. Just remember that it needs slick and tight to shift well. So you will have to hold the tranny, or go very slow while rotating the drum. Then you can physically see the tranny working or not. Sometimes you have to kinda nudge the forks over the little bumps in the drum because of the way it is sitting and its sorta dry.

[Gdkarma]

I've put it together, taken it apart, put it back together a dozen times to try and find something obvious that would cause the prior problem. I am going to grab a buddy this week and put everything back into the case and try to do like you suggested, just shift through the gears and look for anything odd. It also would be nice to have this other person look over things and make sure I'm not missing something!

Thanks for the help this far!

[Gdkarma]

Well, fingers crossed, I will find out if it's fixed or not this week. I had a buddy help out, and it appears to shift through all gears and looks okay. I should have the cylinder and piston this week to assemble, and she's ready to put back in. After it's all said and done, it really wasn't as bad as I thought it would be to tear apart the cases. It just took some patients and a manual, and everythings seems pretty straight forward. I think the worst part was getting the damn swinger bolt out. I hope like h*ll that putting everything back together goes smoother.

I say that now, and it will probably grenade the first time I take it out.........lol, probably just jinxed myself! Thanks for the suggestions thus far, and wish me luck!

[jenndnn3]

How did everything go?

[ATC250RNUT]

i have a 83 250r when its on jacks its goes into 5th gear, but when i put the jack away and put it on the ground it will not go into 5th gear. Has anyone had this problem?? If you can help me i would appreciate it. Thanks