by dogger315 on 02/27/2010
This is part four of the CR250 engine build and will cover the assembly and installation of the kickstarter, idle wheel and gear change mechanism.
To assemble the shift pawls and springs, coat the springs, plungers and pawls with transmission oil. Insert the pieces into the shifter and place the completed assembly into the plate guide. Place the assembly aside.
Mount the previously completed plate guide into the end of the shift drum center (use a small screwdriver to depress the shift pawls until they seat into the shift drum center). Apply a locking agent and torque the three bolts to 9 lb.ft.
Install the return spring, circlip and thrust washer on the gearshift spindle (first picture) and install the collar on the shifter (line in second picture). Apply grease to the gearshift spindle and install it into the case. Use a soft mallet to coax the spindle until seated.
Finally, install the thrust washer and small spring at the opposite end of the assembly and insert the whole assembly into position in the right center case and wind the return spring clockwise until you can insert the spring end in the hole in the case.
Next up is the idle wheel. Coat the idle wheel bushing with transmission oil and Install the idle wheel bushing and idle wheel on the countershaft. Spin the wheel, it should spin freely and quietly along with the kickstart large ratchet wheel. If the idle wheel does not spin freely and quietly, remove it, turn it over and check it again. This is the functional check for the idle wheel and kickstart disengagement.