gear box reassembly

Hi All , I have an 84 WR250 air cooled, Have had the engine apart on reassembly the final drive bearing behind the front sprocket is fouling the gear box gear behind it unless you leave it proud of the case if you tape it home it fouls the gear . Any ideas anybody. The gear has a very small flange on it that should touch the inner race of the bearing before the outer case of the bearing can foul the gear ?.

http://docs.husqvarnaoutlet.com/parts fiche/1984 ALL Parts.pdf
Page F-2

Thanks, i do have a parts book but all spacer seem to be in the right place. Has me a bit baffled .

Can you post a pic? I don't think the output shaft bearing #8 is supposed to be loose enough to tap in or out. It should be a heat to set bearing with the retainer #9 keeping it from falling through. You are right that the gear#41 has the shoulder to the outboard or right side of the case. When assembling the cases with the correct tool, it may take some tapping of the cases with a rubber mallet to get them to close straight. And you should turn the tranmission assembly with whatever part of the shafts you can get a grip on as you are tightening it up. That bearing should be only as wide as the case is thick at that area. Chris

Hi Chris thanks for the input , Don't know what i was doing wrong on the forth time of re assembling it all slipped together perfectly something obviously just not quite seated correctly.

SOmetimes repetition is the key. Glad you got her together. Time for a ride and a pic. Chris

Very soon i hope.

Can you post a pic ?

Couple Questions?

1.) Is that a new bearing going in the case? Sure you have correct size? Not a chinese bearing that wasn't machined to fit properly? If you have old one does it fit tight?

2.) If it is still lose? Could be that the bearing at some point spun in the case?

3.) Here is couple of solutions:
A.) Take case to machinist and have him internally Knurl the surface so bearing will press back in. (I did this with a bearing that spun in a Suzuki RM 100 case).
B.) Coat case area where bearing presses in with JB Marine Weld and wipe excess off. Let set for day or two.
C.) Go get some sleeve retainer. Looks like loctite but is green color. Activates with no air. Let sit overnight.

Hi there not a problem with the bearing spinning, the bearing was fouling the gear on the output shaft all sorted now , many thanks.