Maintenance & Technical > KX500 Original

Tight countershaft

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yeomans:
Hey all,
I'm in the process of mating my cases back together after a crank rebuild.
I have the gears, forks and drum in the case. Gears are in neutral and everything spins freely as it sits.
When the other case halve is dropped on everything still spins freely like it should.
The problem arises once the case bolts around the countershaft begin to tighten and the shaft locks in place, and won't rotate freely any more.
I let the pressure off the bolts and the shaft once again spins freely. :?
Two things go through my head:
The  countershaft bearing isn't completely driven in square to the case or,
I had the oil drain re welded and there might be some warpage of the case?
Anyone experience anything similar before?

Any thoughts?

Motorrad:
Did you forget the one shim in the trans that likes to fall off?

yeomans:
I think everything is in place, Been looking through the manual and online. The 88 models on have a washer on the mainshaft that the earlier 86-87 motors don't seem to have.
Kinda stumped on this one. Is there another shim you speak of?
As soon as I tighten the last few bolts in the case around the countershaft it seems to lock in place.
It's literally the difference of 2-3 turns on the bolts and having the shaft rotating freely and being locked in place.

yeomans:
I haven't been able to trace any image or part number for a shim within the 86 crankcase.
The manual says however that when splitting the crankcase be aware of any possible shims between the transmission and the left crankcase. But doesn't show a photo or a exploded diagram with any shim.
Anybody know of any shims that were in the 86 crankcase?
Starting to believe this might be my issue.

Motorrad:
Hmm. Let me think. I didn't realize we were playing with an 86.

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