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Posted by: juan91382
I am new here and I have owned an atc250sx since 2000 and it has been a blast.
About 2 years ago, my father took out the side gear case and incorrectly positioned a part which caused it to not have 5th gear when he put it back together. Everything worked fine except 5th gear was like being in neutral, but all other gears worked perfectly.........
We took the side gear case off again to try to fix the 5th gear problem, and found that he incorrectly installed a small bushing which was causing the problem. Well, we put it back together and 5th gear now worked, but 2nd gear began making a clunking noise when under load. We also noticed the kick starter was not working properly. We are assuming that we did not put the gears in properly or maybe something is not alinged correctly. Right now I have the right side cover off and the side gear case removed trying to see what we did wrong when we put everything back together.
The gears look good, and we were thinking if everything must be alinged before inserting the side gear case or it doesn't matter.
If we reinstall everything all the gears work great except 2nd gear which seems to make a clunking noise and nuetralizes, then it suddenly clunks back in.
The 250sx has 5 forward gears which are SL-1-2-3-4, well looking at it this way the gear that is clunking on mine is the one after the SUPER-LOW (SL) which is 1, well I call it 2nd gear. Just so you guys know exactly which gear I am talking about.
Does anybody know what might be the culprit, any help will be appreciated.
Thanks in advance!!
