Noise from transmission

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2/24/2018 11:34 AM

Ok guys. I have a 2002 cr250 engine out of the bike and the clutch case is of. When i spin the mainshaft while the engine is on the workbench straight it sounds fine in neutral and in gear, but as soon as i lean the engine over to the right then spin the mainshaft there is a clunking noise from the transmission and it feels like the mainshaft is being slightly caught on something inside the transmission. The previous owner done a rebuild on the engine, could he have left a washer out of the transmission or is this normal. THANKS ALOT.

UPDATE...just checked it further and 1st and 2nd gear clunking then 3rd is clunking and stiff to turn and 4th and 5th runs perfect

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2/24/2018 12:25 PM

I would take it apart and check it. Sounds like something is loose or the shift forks are worn.

Paw Paw

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2/25/2018 4:32 AM

Just split the cases havnt gone through the transmission yet but take a look at these pics of the gear drum is those what look like gouges on the top and bottom normal?Photo

Photo

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2/25/2018 5:25 AM
Edited Date/Time: 2/25/2018 5:26 AM

That is normal casting roughness. Nothing that would cause you any problems. None of the forks ride there. These parts are case and then machines.

Paw Paw

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2/25/2018 5:30 AM

Just noticed therea alot of play when u put ur finger on the inside of this bearing where the drum sits. I wonder if this could be the cause of the problem?Photo

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2/25/2018 10:26 AM
Edited Date/Time: 2/25/2018 10:27 AM

Those normally have some movement in them, but looking at the other bearings in that photo I see a jot of crud in them and that is not normal. With that in mind, all the bearings may be worn.

Paw Paw

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2/25/2018 10:34 AM

Thanks. I am going to change all bearings. But on the last pic with the needle bearing there is excess movement in my opinion. And look just to the top of the bearing where there is a little hole. Well there are score marks on the inner case and i dont think anything should be toutching the inner case like that whatsoever.

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2/25/2018 11:28 AM

That bearing may be set in too deep thus allowing the drum to make contact with the case.

Paw Paw

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2/25/2018 12:18 PM

YOU ARE NOT GOING TO BELIEVE THIS!!!!!
just took apart the transmission and found 2 spline washers missing from the MAINSHAFT
and the circlip and spline washer on the countershaft are the wrong way around.
HOW WAS THE BIKE EVEN ABLE TO GO THROUGH THE GEARS WITH THIS WRONG. i just cant believe how some people are so negligent when it comes to stuff like this. CANT BELIEVE IT LOL LOOK AT THE PIC TO SEE WHAT I MEAN.Photo

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2/25/2018 12:44 PM

That explains a lot.
Good luck.

Paw Paw

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2/25/2018 12:48 PM

Just cant understand how it was still able to shift through the gears ok. Yes there was a noise but it still shifted through them all good even when the engine was running lol.

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