Posts
72
Joined
3/2/2024
Location
Lima, OH, USA
Edited Date/Time
3/2/2024 1:44pm
99 KX250 Engine Rebuild. While rotating, the idle gear slightly clicks against the shift shaft spring. It does not hinder rotation, only makes a soft click from the idle gear teeth brushing against the spring. The shift shaft is fully inserted and the idle gear was installed with the shouldered side facing inward. Is this normal? Any help would be appreciated. Thanks!
Did you install a snap ring on before the idler gear? Should be one one both sides.
Did you mean kick start shaft spring?
It would be the small spring on the upper portion of the shift shaft.
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Make sure the shift shaft is seated properly as far left as it can go, that stepped collar (ref. # 92152 in the diagram above) may not be seated correctly, pushing the shaft shaft to the right a few mm's.
That, or with it lying on its left side the shaft might be getting pushed up toward the clutch?
Sorry if that seems Captain Obvious but you never know.
This sounds like it could be the issue. I'll check it out and let you know. Thanks @chuck356!
I have clearance between the end of the shaft (where the shift lever attaches) and the blocking it rests on, if that is what you are referring to. Thanks for the input!
Cool and yes, that's what I was talking about. Obviously couldn't see in the picture but it wouldn't be the first time I've seen one bumped over inadvertently.
After further review, there was a snap ring on the inside as you mentioned, however, I did have it installed previously. Chuck356 properly diagnosed the issue. Thank you for taking the time to help me with the issue, Million121.
The stepped collar was not properly seated as you mentioned. The issue is now resolved. Thanks for taking the time to help me with the problem, chuck356!
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