I'm rebuilding my 90 250 motor. I got the bottom end all put back together. I feel as though I got everything right as I had the book next to me all the way through it.

I put the gear shift lever on it after I put the clutch together and figured I could **** through the gears to see if it was functional.. (Motor on the bench and without the side covers on it) I am able to go 1 firm click up from neutral and then one firm click down which should be 1st but is back to neutral. Other then that It will not give me a firm click into any other gears even with moving the crank and internal components. Is this normal or should I go back into the bottom end yet again? Also I was not able to find anything in the manual on how far I should put the clutch screws in, I put them to where they were flush with the top plate piece of the assembly Is that too much?

Well I don't have any fluid in it currently.So I guess tomorrow I'll put my clutch cover on, fill it up and try shifting through the gears while someone rotates the crank. (I'll bring the wife along  ) The only thing that I could think is that maybe I didn't get the forks in the shift barrel (for lack of better term) just right.

Not sure on the 250 but on the 500 trans you really need the cases together as it supports the dowel pins the shift forks sit on which keeps everything spaced properly and able to shift, otherwise they bind unless you hold them apart from each other. 

You can put a little type F or what ever you are going to use for tranny lube on it if you want but if you're worried about it not being done right I'd put the cases together dry with 2 or 3 bolts and make sure the tranny works then pull them back apart and seal them up with 1211 like they should be.

I think I figured it out!! It shifted fine before I put the actuator piece and its holder onto the shift barrel and case. I think I could of gotten piece 8 and 9 on the attached diagram reversed. because it looks like they slightly come into contact with number 12 which looks to be what is keeping it from shifting smoothly. If I remember right parts 9 and 8 have one side of the gap, for part 10s, is larger then the other side. does this make sense to anyone else but me?

I will be able to on Wednesday. I'll end up taking the clutch assembly off and take some pictures. then maybe Ill take the retainer piece off and see if it will shift correctly.

Thanks for the help.

heres the thread for the problem i had, you should look into it if you split the cases.


http://www.suzukiquadracerhq.com/lt250/advice-for-a-shifting-problem/


by the way i used a manuel when i listed the parts numbers and noticed that your picture had different numbers than mine so that might be confusing unless u have the same part page i used.

ok, so I have some great news. I took the clutch assembly back off and after playing around with the gear shift assembly it started working just like it should. All i had to do was have someone spin the front sprocket, and in the right direction for that matter, and I was able to hit all of the gears smoothly. As soon as I get the stator and RM bearing and billet washers I'll have it all buttoned up and done. 

Thanks all.