Maintenance & Technical > KX500 Original
transmission jumped in gear from nuetral
kwacker83:
I don't know how I missed it before, but El Snorro had a link to a free FSM download here. I will let you know what I find later.
Foxx4Beaver:
yeah I forget he posted that too sometimes...keep us posted.
sandblaster:
SHIFT FORK AND SHIFT DRUM SPECIFICATIONS
Scroll down about half way down the page to find it.
http://www.oem-cycle.com/forum/viewtopic.php?f=49&t=344
kwacker83:
Well I lucked out some. Every tolerance in my transmission for gears, drum and forks(checked for straightess) was right at the tightest side of tolerances. For a 92 it either was barely ridden(which is what I was told) or had everything new installed. I assembled everything in the case half and clicked through gears and rotated gears slow, in two positions(first and nuetral I assume) everything seemed fine. Clicking up through gears the forks slid sideways fine but I could only rotate the gears half way around before they bound up. I noticed the dogs were not engaging into one of the gears. I pulled both shafts out with gears together. Fifth gear was not spinning. I could barely turn it using all my force. I removed circlips on gears and they all slid off easy except this one needed to be tapped with a rubber mallet.
So all I need is the gear, shaft and related gakets and seals for reassembly. I am going to replate cylinder and do top end.
Thinking about how this could've happened to a tight gearbox that was shifting fine I believe when I had the bike parked resting it was leaned far to stator side on a rock.I rolled down the trail and popped bike near bottom (short distance) and was revving out bike. The bike was warmed up and I assumed was alright. I guess it takes a bit longer to get oil in parts than I thought from it being leaned over.
For now on I will never rev a bike more than the small burp needed to keep it clean while sitting in nuetral.
Thanks for the help. I am glad there is still a lot of good info out there for this bike. I love this bike and plan to keep it in my family.
Foxx4Beaver:
awesome, good to hear!....
since you're gonna have it replated and new top end...now's also the time to replace all the bearings and seals in the bottom end too while it's apart.
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