It may be possible to put the small idler gear in backward as both spacers/washers & bearings are the same either side of the shaft. Can't say for sure because i have never tried putting it in backward lol
I hope for your sake it's an easy fix
-- Edited by TT-R250M on Monday 18th of February 2013 06:42:53 AM
__________________
2000 TT-R250M-
Spoiler
Ported & polished, 73mm bore, Wizeco piston, US header pipe, FMF Q4, #150 main jet, #52.5 pilot jet, throttle stop screw adjusted, larger snorkel, GYT-R air filter, NGK Iridium spark plug, 14/51 gearing, NOS +
Thanks very much for the info on the flywheel puller. I finally got that off and went to replace the sprag clutch. Both idler gears and all bearings looked good. No broken teeth or anything, but after I got everything back together I tried to start it and got a really loud clunking sound. Now it doesn't sound like it's even engaging the starter motor. The starter motor is working, and the teeth on that also looks good, but it seemed like the noise was coming from the larger idler gear area. Any ideas? I'm kind of stumped right now. I really don't want to take it to a shop and I would much rather do this myself. Changing the sprag didn't seem too difficult from all the reading I've been doing about it, but it's kind of frustrating me and I really want to go riding.
You know I was just thinking that maybe I put the small idler in the wrong way. I don't know if it's possible to do that or not, but I was pretty well spent from putting everything back together. I was trying to be careful with what I was doing but it was getting later in the afternoon and maybe I could have done it. I dunno. I'll have to check it out if I get a chance during this week.
I finally got my '03 running! After all the starter clutch issues and the non starting/ carb problems, it was getting a little old, but I cleaned out the carb as well as I could and replaced most of the parts in the lower part of the carb, but it seems to have been the diaphragm pump and needle valve that could have been the culprits. I also went back to the stock jets which were 137 main and 50 pilot jets. Once I got the carb back together and some gas in it, it was a little hard starting at first, but it finally fired up and starts well now. Just a bit of choke and starts right up. I was ready to find someone to take a look at it to see what the problem was. It felt really good to get this bike fixed myself. This site helped with giving me ideas and information that put me on the right path. It took me a while, but I haven't had a huge amount of time to work on the bike. I will get some pictures of the bike in the next week or so.
Glad that it was an easy fix and it's all sorted now Charlie
For other owners- the problem was the small idler gear was in backwards. Take note of this for when you have to do one The other problem was the Mikuni #140 and #52.5 jets- must have been too large. Also, the diaphragm pump faulty wouldn't have been helping or the float valve ''gunked'' up.
Thanks for updating this thread for other owners Charlie, enjoy your ''new found'' toy
Jarrah
__________________
2000 TT-R250M-
Spoiler
Ported & polished, 73mm bore, Wizeco piston, US header pipe, FMF Q4, #150 main jet, #52.5 pilot jet, throttle stop screw adjusted, larger snorkel, GYT-R air filter, NGK Iridium spark plug, 14/51 gearing, NOS +
