Maintenance & Technical > KX500 Original

KX500 on the street-lost shifting and 3rd gear...

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Rick james:
How goes it! First post here, picked up a CA plated KX500 about a month or two ago.  After all of the nickel and dime junk that needed repairing and a rejet to 168/58/1.5/3rd clip, I've gotten it running pretty decently.

Anyway, on with the question:  I was rolling along around 25mph and went to click up into third when she went into neutral on me.  I pulled over, fiddled with the shifter for a while, got it to go back down into first and through the gears again with the engine off, so I tried to take off again.  I was taking it slow, but since it missed another gear, I pulled over and my friend came and got me in the pickup.  Playing with the shifter now, it springs both up and down as it's moved, but it doesn't feel like it's engaging anything.  I haven't disassembled the clutch side cover or anything yet. My clutch and brake levers appear both to be 90's vintage, so I know I wasn't getting full clutch disengagement due to the thing flopping around, but the gears have been shifting well enough recently.  I had some missed shifts at first, but changed the oil and countershaft seal and O-ring recently when I discovered a leak there and it's been clicking through the gears happily since.

Any tips on pulling the clutch side cover?  Is anything going to come flying out at me?  What are the odds that this is a simple fix versus something I need to split the cases to repair?  I didn't hear any nasty noises or feel anything really let go when it occured.  I'm somewhat reluctant to even pull the clutch cover right now, as I don't really want to get deeply involved with taking the thing apart if I don't have the parts to fix it available.  I've learned my lesson that 90% of what you need for this thing parts wise needs to be ordered. 

I have searched a little bit, and have seen everything from it just needed a wiggle on the shifter linkage to dogs/forks/gears and a full rebuild. TIA.

sandblaster:
 It sounds very similar to a issue I had on a K5 and it was a sheared circlip that holds 3rd gear on the shaft.
Of course you should always check the simple things first and removing the clutch cover is a good place to start.
Nothing should shoot out at you.
If it does, be sure to get it on video so we can all watch  :lol:

Motorrad:

--- Quote from: sandblaster on July 13, 2013, 05:58:07 AM --- It sounds very similar to a issue I had on a K5 and it was a sheared circlip that holds 3rd gear on the shaft.
Of course you should always check the simple things first and removing the clutch cover is a good place to start.
Nothing should shoot out at you.
If it does, be sure to get it on video so we can all watch  :lol:

--- End quote ---

some times the little forky thing under the clutch cover pops off the rockery thinggy.    the white plasticky thingggy wears  or........  causing it.







Another Plated CA K5.   man. Im starting to feel like I have a Belly Button bike.

sandblaster:

--- Quote from: Motorrad on July 13, 2013, 06:17:52 AM ---Another Plated CA K5.   man. Im starting to feel like I have a Belly Button bike.

--- End quote ---

If you have a belly button bike it must be a outie..... There out there, just not as common as a innie  :-)

Rick james:
Well, I finally got time to remove the clutch cover.  The spring that holds the roller on the shift wheel was broken, so that's one issue.  When I move the shifter up and down it doesn't go into second. Looks like at this point all it's able to do is shift from first to neutral.  Any ideas on what I should order before I split the cases?  I'd like to have just about all of the parts I need before I get into it.  Any lists of what I should order as far as just the supplies to split the cases?  I'll definitely get the new circlips for the gears, but anyone have any other items that should be replaced? Should I just order the second gear shift fork as well?  I had been noticing some missed 2nd gear shifts before this happened, but I had attributed it to wearing soft boots instead of MX gear while tooling it around. Any other must replace items that I should do while I'm in there?

Also, I noticed cracks in the clutch basket and almost just s**t my pants when I found out how much the OE one is.  Are these cracks typical or should I replace it?


TIA,
rich

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