Motorcycle Repair: Transmission, yz 85, shively

Question
I just put together my boys 2003 YZ 85 after shearing the axel shaft. I have had this motor apart several times for trans problems but this one has me stumped. The engine runs great and I have first and second gear but a huge problem getting from second into the other three gears. It is almost impossible to get from second to third and from third to second. What did I do wrong? Both gear clusters are new and all parts were inspected for any wear or damage.

Answer
Hi Todd,

Q:  "...The engine runs great and I have first and second gear but a huge problem getting from second into the other three gears. It is almost impossible to get from second to third and from third to second. What did I do wrong? Both gear clusters are new and all parts were inspected for any wear or damage."


A:  Were measurements taken on transmission parts to verify if wear is within service limits? Or, were the parts visually inspected?


I would need to inspect the transmission to accurately determine the cause. I would be guessing to answer, which is fruitless.

Get a copy of the service manual. Measure everything precisely according to the manual. If all parts wear is within specs, it'll be an assembly problem. Oversights happen to everyone on assembly.

Respectfully,
Mark Shively