How do I know what order to install transmission gears?

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10/18/2017 6:28 PM

I gotta cr125 that I'm rebuilding. I got the bike in a box and the engine was in pieces with all the transmission gears scattered around randomly. How on earth am I gonna figure out how to put the gears in exactly how they go and how am I gonna know what's missing? The gears don't have the parts number written on them so I can't really look at the parts assembly except by seeing what something 'kinda looks like' and hoping it's right. Is there a good way to do this or do I just wing it and pray it runs right when I crank it up so I don't have to tear the engine apart again?

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10/18/2017 6:35 PM

A service manual is your friend.

Paw Paw

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10/18/2017 6:53 PM

Paw Paw wrote:

A service manual is your friend.

Paw Paw

It would show the same thing as the parts assembly I have

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10/18/2017 7:06 PM

so each gear has a certian number of teeth, that when you look at the parts diagram then look at the part description and it will say the number of teeth , and its really just a puzzel, are you good at puzzels?

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10/18/2017 7:14 PM

pete24 wrote:

so each gear has a certian number of teeth, that when you look at the parts diagram then look at the part description and it will say the number of teeth , and its really just a puzzel, are you good at puzzels?

Hmmm I just realized that. Thanks for the tip that should help me figure it out.

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10/18/2017 7:15 PM

But what about the different collars? They all look the same on the diagram. I honestly can't tell a difference in any of them.

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10/18/2017 7:16 PM

And the washers

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10/18/2017 9:10 PM

When u think u have it figured out put the tranny in the motor, leave the crank out and assemble the 2 motor halves and go through the gears to see if it works. I always do this when I have the tranny out to make sure it works and if u have a problem it's easy to tear back apart

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10/18/2017 10:04 PM

print off a parts fische and put it together how its laid out

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IG @jaredkeller96

10/19/2017 2:09 AM

Yep look at the exploded view. My first one took a while to figure out. Best tip is to lay out all the parts on the table and study them. See how many dogs and boss features they have. Then start identifying them in the exploded view.

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2009 Kawasaki KX450F
2009 Kawasaki KX250F
2002 Suzuki GSXR 600

10/19/2017 9:54 AM

Ok good news is that I do have all my gears and I'm not missing any. I've got them all labeled with their part numbers so I shouldn't have any problems there. Now I gotta figure out the washers and collars and other small bits.

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10/19/2017 12:57 PM

Took a while but I got every single thing sorted out and in order except the washers. I saved the hardest part for last.

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10/19/2017 1:14 PM

Yes I got in all together in perfect order!!! Now does anyone know how to clean the gears and stuff before I put it in the engine? They got dirt and crap all over them.

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10/19/2017 1:15 PM
Edited Date/Time: 10/19/2017 1:16 PM

z71will wrote:

Took a while but I got every single thing sorted out and in order except the washers. I saved the hardest part for last.

The service manual will give thickness Service Limits for each washer. Compare the sizes in the manual to each washer and you'll be able to piece it together. Also the OEM parts list will sometimes give ID/OD

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10/19/2017 1:16 PM

Should be able to spray them down with brake clean etc. as long as all your clips and washers are in they won’t come apart

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IG @jaredkeller96

10/19/2017 2:36 PM

Or send them to a professional like us and have them polished. Haha

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IG @jaredkeller96