Maintenance & Technical > KX500 Original
transmission jumped in gear from nuetral
kwacker83:
So I drive up to a lookout on my 92 kx500, I brought my step son riding(xr70) so my day involved a lot of nuetral sitting and revving to ease my fears of fouling a plug lugging all day. My bike sat for about 25 min. The hill down was rocky and I was waiting at bottom for him, I got a little rev happy this time cleaning it out and out of nowhere it jumps in gear and locks up after lunging forward a few feet. It fired with clutch pulled but died as soon as let out. I had to get towed back to truck holding clutch lever. The shifter moved up and down but would not click or find nuetral no matter how much I rocked it. The bike was shifting fine every ride till this.
Upon getting home I filled the transmission up with wd40. The next day I rocked it enough and found nuetral. The shifter seemed slightly better as it clicked(but not a solid normal "click")first, nuetral, second, but stop trying to go into 3rd. At my friends shop we took off clutch cover and clutch and all springs appeared fine, he split the case for me and said all gears slide fine and nothing is chipped or broken. Everything looks clean.
Sorry for long post I just want to be descriptive, I have searched problem and was hoping it would be one of the springs behind clutch. Can anyone point me in a direction of where to look or check. Thanks
Foxx4Beaver:
how do the shift forks look?...possibly could've bent one.
check the small spring on the gear change mechanism too...there's actually 2 springs in there...one is part #92081-076 which is a "return" spring , and the other is #92145-1368.
Foxx4Beaver:
also, being a '92, there's a good chance most of that tranny is original...meaning there could be a lot of worn parts and contributing factors.
This was the case with mine a couple years ago...mine started jumping outa gear due to a broken snap ring...but once I pulled it apart, I found several worn gears, worn and bent forks, worn shift drum....so instead of just replacing a few things, I replaced the entire tranny and gear change mechanism, because I didn't want to mate any new parts to any old parts.
I really doubt you'll need to go to that extreme, but be sure to check everything really well....if you don't have a service manual, get one...as it'll give you all the wear tolerance specs on all the tranny parts.
kwacker83:
I am heading to the shop today to check things out myself. I know I need a service manual. Where is the best place to get one?I really would like an original book.
Can anyone give the specs to check on shift forks and drum?I am probably at a standstill till I can get the tolerances for gearbox.
I have seen bikes that pop out of gear or miss a gear or just shift notchy but this is my first time having a bike that seemed fine jump out of nuetral then lock up and it not shifting into third. Thanks for the help.
One more question, did Kawi not use a gasket on main case halves? This bike did not have one.
Foxx4Beaver:
--- Quote from: kwacker83 on January 03, 2016, 01:13:56 AM --- I am heading to the shop today to check things out myself. I know I need a service manual. Where is the best place to get one?I really would like an original book.
Can anyone give the specs to check on shift forks and drum?I am probably at a standstill till I can get the tolerances for gearbox.
I have seen bikes that pop out of gear or miss a gear or just shift notchy but this is my first time having a bike that seemed fine jump out of nuetral then lock up and it not shifting into third. Thanks for the help.
One more question, did Kawi not use a gasket on main case halves? This bike did not have one.
--- End quote ---
you can find used and new manuals on e-bay all day long...'88-'04.
no gasket between the case halves...a good layer of Yamabond-4 or Threebond case sealer is the only thing used to seal it up.
Navigation
[0] Message Index
[#] Next page
Go to full version