1981 kx250 shift drum installation

[Mr.]

Hi I was wondring if anyone could tell me how to get the shift drum in a 1981 kx250. Th problem is the studs on the shifter forks stop the drum from going all the way down into the case to get both halves together. It would seem logical to take the gear side off and then press it back together with the cases but for the life of me it wont come apart i need help!!!

[Mr.]

If no one knows this does anyone know someone who does?

[sandblaster]

I don't have any Clymer shop manuals for that year KX250 to tell you if there is something special.
Do you have a shop manual?
Are you certain that all the parts came out of that set of cases?
If so, have you checked to see if the drum bearings are correctly seated in the case?
Have you tried fitting the drum to the bearings to be sure there is no interference problems?

[Mr.]

Yes all the parts came out of the same case and no i do not have a manual. I believe the bearings to be correct im just having trouble meshing the drum with the forks

[Mr.]

what im trying to fit together

[Friar-Tuck]

Hey there Mr.!  
 I believe you have to remove the bolt from the shift drum and put the trans together
(shift forks, drum,crank, trans et al) on one side.   Then put the case half's together.
   I would highly recommend scrounging up either a Clymer or factory manuals for your bike.  Even if you are just planning on flipping it.   One mistake may cost significantly more than the money spent on a manual.  I only say this to save you the frustration I went through. You can always recoup your investment (on the manuals) on the back end when & if  you  sell the bike.
    I'll snoop around youtube and look for a vid for some kind explanation.  Well a better one than I can give... 
 http://www.bing.com/videos/search?q=rebuilding%20the%20bottom%20end%2C%20two%20stroke&FORM=BVLH
  Signed,
 Been there, done that, got the T-shirt.  
 Tuck\o/
  

[Mr.]

If that is the case then how did it come apart?

[sandblaster]

Without the manual I can't help you with that drum problem but I'm sure there are those that can help.
Just a few observations though, it looks pretty dirty inside your cases.
I could be wrong as it can be hard to tell from a computer pic but if there is any grit.... get it out now while you have the option.
Otherwise that stuff will go through your bearings and you'll be very disappointed.
Also, it looks like the bearings might be a bit rusty?
If so, now is the time to replace them...

[Mr.]

Its is dirty because i had to clean off the new gasket i put on it because it dried before i could get the case back together and the bearings aren't rusted its the packing i used for them that makes the color. also i just figured it out while in the shower the gears have to go in the other side of the case first... i always miss the simple solution.

[sandblaster]

Believe me, your not the only one who misses the simple solution... 

[Mr.]

Case is now together anyone know how to put the gear change mechanism together?