Maintenance & Technical > KX500 Original

Assembling transmission and I cannot get it to shift

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Mike Grant:
Hey guys.....finally started to tackle my engine rebuild this weekend and I have run into a problem that is stopping me dead in my tracks. I installed new bearings in the transmission + cranks bearings this morning and have moved onto assembling the transmission. I have the transmission completely assembled in the right case half along with the external parts on the other side (shift star + detent)

The input / output shafts turn smooth but cannot get the shift mechanism to work by using the shift shaft and shifter (need more hands to hold the engine secure which I don't have any at the moments. I also turning the shift drum with Vice grips which I  electrical taped the hell out of the vice grips jaws to avoid damaging the bushing surface......didn't work either

How the hell are you supposed to run this thing through the gears prior to assembling to make sure everything works ?

DoldGuy:
Mike,

I assemble both case halves together, and then will turn the output shaft while shifting thru the gears to confirm I have all gears....

Hope this helps,

DoldGuy

Edit:

With your current setup if you remove the shift fork pins can you move yhe shift drum?

Mike Grant:
Yes If I remove the shift fork locater pins I can turn the shift drum

DoldGuy:
Can you spin both the input / output shafts with the pins out & the shift forks riding in the slots? If you are sure you have the forks in their proper spots, I would assemble both case halves together & check the shifting by spinning the output shaft.

DoldGuy

Mike Grant:
Yep I can spin both shafts and there is no binding or any other problems. I took everything apart and quadruple checked all shift forks are correct against the manual and checked both gear clusters that all washers/gears are in the proper position. Everything is 100% correct according to the manual. Biggest problem I have right now is I don't have shifter to attach to the shift shaft so I was trying other methods to make sure this thing was going to shift before it went back together

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