jaffamaster Posted November 13, 2012 Report Share Posted November 13, 2012 Hi Folks, I've got a problem with my 2004 Rev 3 250 - after a full rebuild to repair the side casson and replace main bearings etc i've now encountered a problem with the gear box after the rebuild - the issue is when moving up through the gears from either 1st into 2nd or neutral into 2nd its like hitting a brick wall and the bike stops nearly putting me over the bars, once the clutch is pulled in and let out it appears to free itself and rides as normal - could it be the selector, the gears are very notchy? the selector drum is slightly worn as well as where the selector forks, but this issue did not exist before the rebuild, so maybe something is in the wrong position? Hope this makes sense, i did try searching other threads but couldn't find anything as specific... the issues doesn't appear when moving back down the box, only on the way up... Best rgds Nick Quote Link to comment Share on other sites More sharing options...
copemech Posted November 14, 2012 Report Share Posted November 14, 2012 Sounds as though there is a shim washer out of place, allowing things to move about enough to actually enguage two gears at once(or next without fully disenguaging the other.) Quote Link to comment Share on other sites More sharing options...
jaffamaster Posted November 14, 2012 Author Report Share Posted November 14, 2012 Sounds as though there is a shim washer out of place, allowing things to move about enough to actually enguage two gears at once(or next without fully disenguaging the other.) Thanks mate, I think you were correct, split the motor again to find the main shaft teeth stripped :-( i must have missed something during the rebuild, one if the bearing on the shaft was split in two as well... no other apparent damage, new shaft or donner gear box required. Does anyone know which gear boxes will do, i see someone is selling a 1995 Beta Techno 250 Stock OEM Transmission Trans Gear Drive on ebay that look similar? Quote Link to comment Share on other sites More sharing options...
copemech Posted November 15, 2012 Report Share Posted November 15, 2012 Thanks mate, I think you were correct, split the motor again to find the main shaft teeth stripped :-( i must have missed something during the rebuild, one if the bearing on the shaft was split in two as well... no other apparent damage, new shaft or donner gear box required. Does anyone know which gear boxes will do, i see someone is selling a 1995 Beta Techno 250 Stock OEM Transmission Trans Gear Drive on ebay that look similar? Yea, well the damage is likely the result of the extreme forces upon enguagement of two ratios simultaniously. You still need to find the cause! A lot of parts may interchange, but you will need to check the numbers to be sure! Quote Link to comment Share on other sites More sharing options...
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