Attn: anyone who has built honda bottom end

[sheefreak]

I am helping a friend rebuild the bottom end of his CR250. Everything has gone smooth(I thought) until we went to tighten the case bolts. Once they are tight, the back gear cluster locks up. Can barely spin w/ a sprocket on it. Just barely loosen the bolts and it free's up. I have had it apart several times to recheck, and everything checks out. The forks are all in the drum correctly, transmission shifts through all the gears, all washers and clips in place where they are supposed to be. The crank and driven shaft spin just fine when all is tight. My friend is trying to reuse the gasket as it is still intact. I couldn't see thickness of the gasket making that big of a difference (as compared to new) as it is the one that came out of it. Any helpful information from anyone who has ever split and then assembled verically split cases would be appreciated.

[thegroup]

sounds like either something isnt lining up or ur tighten 'em to much

[sheefreak]

Yeah, I thought the same thing, but that isn't even torqued, just snugged, and I have had it apart several times to check to make sure everything is lining up and no luck.

[sheefreak]

Anyone else?

[reded]

Are you using all of the alignment pins,if you don't sometimes they will bind. Also, make sure the bearings are completely bottomed out and straight in the case halves.

[locogato11283]

its been a while since i had my old cr500 engine open but im guessin there are clips for the tranny just like in the banshee motor. might check those out too..

[dirtplay1975]

My best guess would be that you could possibly have a washer on the wrong transmission shaft causing it to bind up due to being too wide for the cases, or maybe a gear that isnt seated fully in the transmission on the shaft possibly. Like it was mentioned a bearing could not be fully seated in the case too, one thing you could try is tightes the bolts till it binds then take a rubber mallet or dead blow hammer and tap the case gently around the shaft and maybe even gently tap the end of the shaft and see if it frees up some, the vibration could seat the bearing etc it thats whats causing your binding. Just dont whack on it cause that could cause problems go easy with it.