Assembling transmission and I cannot get it to shift

[yeomans]

Hey Mike, A few thoughts,
If you replaced your circlips on the trans is it possible that a gear may have gotten flipped around during assembly ?
Is the dowel pin on your shift drum still there? Just a thought, if its missing you might not have the drum matched up right on either side of the case.
You are sure all of your forks are sitting correctly in their grooves and nothing is jumping loose on you?
What year is your crankcase, what year is the trans from?

[vagassasson]

I think if the gear in the red box is installed backwards it can cause it to not function properly. I will double check when I get home later

The reason I mentioned it is because it happend to me

[Mike Grant]

The crankcase is an 87.  The transmission was 86 or 87.......he never 100% confirmed with me

The transmission is as delivered to me and I just installed a new pair of roller bearing on both shafts. The only gears that I installed would be high gear and  low gear on the output shaft and second gear input. New Circlips were used

[Mike Grant]

Vagassasson. I passed this information onto the guy who is looking at my engine for me know........appreciate the lead

[vagassasson]

Hey mike I used the wrong picture on my previous comments that was the tranny picture for my 98 kx500.I was comparing the 2 side by side and got them mixed up. Here is the 87 diagram.don't know if it can cause the same issue in your year or not. Sorry for the mix up

[Mike Grant]

Well the guy building my motor thinks I he has it figured out ............mixed the shift forks up on the output shaft.........feel like a retard but at least it is shifting gears fine now

[sandblaster]

If you build motors it will happen from time to time 
Thanks for the update.

[vagassasson]

Yep that can do it to glad to hear you got it fixed

[DoldGuy]

Great news! We All make miscues like that...Now get some video of it...Ringa Ding Ding.

DoldGuy

[Pmcg]

When I rebuilt my motor I put the crank in backwards. I didn't realize it until I tried to slide the drive gear onto the flywheel side of the crank.  Had to resplit the cases.  A mistake I won't make twice!!!

[motojason]

On the last rebuild on my 83 KX250 I put the washer that goes under the idler gear on the output shaft inside the case instead of on the outside because it was shown in the diagram outside of the circlip on the clutch side. It all worked fine until I torqued the case bolts to the proper setting. Then it would lock up solid. Drove me nuts! Took it apart twice thinking it was correct. Then I looked at the kick start assembly diagram and the light bulb went off... This stuff happens.