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74 DT250 first time case assembly
- Jcb1994
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74 DT250 first time case assembly was created by Jcb1994
Hello! I'm slapping together the crankcase/engine for my 74 DT250. I've got the halves together and all that, nothing is binding. I THINK it's all correct, so far. BUT I have run into an issue. I'm getting the shifter hardware on and I'm testing it out. I can only shift up one or down one and that's it. I'm not exactly sure what gears they are, but they're all I am getting. Neither of them are neutral. All shafts still rotate freely in either gear.
What did I do wrong? What can I do to remedy this? Was I supposed to have it in a certain gear before assembling the case halves?
What did I do wrong? What can I do to remedy this? Was I supposed to have it in a certain gear before assembling the case halves?
19 Sep 2021 18:47
#1
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- Enduro nut
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Replied by Enduro nut on topic 74 DT250 first time case assembly
Hard to say with it not being right here in front of me. To my knowledge and experience it shouldnt matter what gear your in when assembling as long as all the gears, shift forks and such are all in "mesh". I know when i test mine out i go back and forth rotating the crank and the drive sprocket shaft for easier shifting and to make sure its actually in gear.
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19 Sep 2021 19:10
#2
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- hackman101
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Replied by hackman101 on topic 74 DT250 first time case assembly
I am getting ready to split the case on my 73 MX250 . It was important so the article said to have the trans in neutral before opening it up. Perhaps it is the same thing for reassembly?? I have not read that far along yet.
1973 MX250
Past rides 45 years ago (and longer)
1964 Honda 50cc C110
1960s Yamaha 65cc scooter
1960s Honda 65cc w/ 90cc engine mashup
1971 DT1-E modified to MX kinda...
Past rides 45 years ago (and longer)
1964 Honda 50cc C110
1960s Yamaha 65cc scooter
1960s Honda 65cc w/ 90cc engine mashup
1971 DT1-E modified to MX kinda...
19 Sep 2021 19:44
#3
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- Jcb1994
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Replied by Jcb1994 on topic 74 DT250 first time case assembly
Very strange, I tipped it onto its side over some blocks with the stator side up. Managed to turn an output shaft with one hand and used the other hand to twist on the shift cam barrel from below, it shifts through gears while doing this. Not sure what's going on here but I'll keep this thread updated. Maybe I had the change levers in wrong.
19 Sep 2021 20:06
#4
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- RT325
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Replied by RT325 on topic 74 DT250 first time case assembly
First thing is the plunger & spring in on the left underneath which holds it in gear & gives the springy lumpy feel changing gears on the lever. Secondly is the teeth of the change arm & mating teeth parts meshed centrally--equal teeth each way. Also you can dismantle or assemble in any gear you like. It make no difference at all. Important though is to have selectors into the gears & selector pins into the drum tracks--that's all that matters as once assembled everything is constantly revolving & moving changing gear. On the bench you'll need to revolve one shaft a little back & forth to get the dogs to engage--either main shaft or output shaft whatever is easiest at the time from which side ya standing to be able to change through 5 gears while stationary on the bench. Good luck.
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- RT325
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Replied by RT325 on topic 74 DT250 first time case assembly
sorry edit edit edit, i'll get it right in the end lol.
19 Sep 2021 20:52
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- RT325
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Replied by RT325 on topic 74 DT250 first time case assembly
Not important #3, any gear its in is fine & same for assembly. Tried 'quoting' your post & adding mine to it but didn't work .
19 Sep 2021 21:00
#7
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- Jcb1994
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Replied by Jcb1994 on topic 74 DT250 first time case assembly
Got it figured out. Pulled the levers off and took the compressed plunger out from the bottom. Flipped it over to its side, turned one of the input/output shafts and twisted the cam barrel and got it to neutral, then put the plunger back in. Flipped it back over and put the shifter levers on (I was off one index before). Spun the I/O shafts and was able to shift through the gears out of neutral.
This was a first for me, very weird. Thanks for the help.
This was a first for me, very weird. Thanks for the help.
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19 Sep 2021 21:40
#8
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