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6254
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11/25/2007
Location
Athens, GA, USA
Edited Date/Time
11/3/2014 9:51am
I'm close to putting my cases back together and watched this video to get an idea of how to assemble the transmission (it was easy to take apart!). Is there a better way of assembling the gears, shift forks and drum and putting into the case? Is it always better to put in the left side case (like the video says)? Should I put the crankshaft in the left case before installing the transmission assembly?
Bike is a 89 kx125 if that matters. There are only two shift fork rods. One rod has two forks.
Bike is a 89 kx125 if that matters. There are only two shift fork rods. One rod has two forks.
When the case halves are together, run about half the case bolts in and then check to make sure the tranny shafts spin smoothly and it shifts through all the gears.
Install the crankshaft first:
Then put the two gear clusters in at the same time:
Then install the shift forks and spread them out:
Install the shiftdrum and rotate the shift forks so that the pins engage the drum:
Install the shift fork pins:
Turn the gear clusters by hand and make sure they turn freely with no binding. Install the Left side case. I use a crankshaft
installing tool to draw the cases together, but you can use a case splitter or case bolts and a mallet. The key is to keep the
two halves parallel all the way down.
I need to make a video of this process someday.
dogger
What size is your 2x4 cradle? I made mine too big..
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I've always done the right side because it's the way I learned, but it doesn't really matter. You have come this far so I suggest you get a crankshaft installer, the tusk one in Dogger's photos can't be more than $60-$75. For the love of God, don't use a hammer...
Don't use the case bolts to put it together, that will put stress on the crank and could throw it out of alignment.
This is what you need: https://www.rockymountainatvmc.com/p/989/17166/Tusk-Crank-Puller-Instal…
Whichever side of the cases has the shift drum, that's what I'd suggest starting with. As Dogger wrote, put the crank in first. I use zip ties or rubber bands to keep the con-rod centered and out of the way (don't want to accidentally get it between the cases as you're closing them up).
Anyone else use a harmonic balancer puller to split cases? Another backyard trick I use.
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