Maintenance & Technical > KX500 Original

Trans problem

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kx5tsi:
Ive got a problem with my 87 kx5

while out riding it seemed as though I missed 3rd gear. Well, i kept riding and kept missing it, now I just got new msr boots and they are a little tall and I was having some trouble fitting under the shift lever. anyways I thought it was my boots and paid no attention to it. All of a sudden I lost all gears, heard some weird noises and lost the feel to my shift lever. I was able to get it into first and get back to the truck, but had no other gears.

I got home and went to mess with it, wanted to start it up to see if I could maybe get somthing to work, and my kick starter is not working, it wont kick down. Now I assume my gearbox locked up for some reason, so I drained my oil and no metal chunks or anything, only a few tiny specks here and there which I assume could be clutch particles? Anyways hopefully somone has some advice for me. I just bought this bike about a month ago and its a bummer for it to break already.

Any help is appreciated, thanks,

kyle

gowen:
Take the clutch side cover off. Check the assembly in there. Maybe snap a pic? Or see what came apart. It doesn't sound quite like a tranny problem, but more a shifting assembly? Get it apart and let me know what you see.

Polar-Bus:

--- Quote from: kx5tsi on September 10, 2006, 02:34:18 PM ---Ive got a problem with my 87 kx5

while out riding it seemed as though I missed 3rd gear. Well, i kept riding and kept missing it, now I just got new msr boots and they are a little tall and I was having some trouble fitting under the shift lever. anyways I thought it was my boots and paid no attention to it. All of a sudden I lost all gears, heard some weird noises and lost the feel to my shift lever. I was able to get it into first and get back to the truck, but had no other gears.

I got home and went to mess with it, wanted to start it up to see if I could maybe get somthing to work, and my kick starter is not working, it wont kick down. Now I assume my gearbox locked up for some reason, so I drained my oil and no metal chunks or anything, only a few tiny specks here and there which I assume could be clutch particles? Anyways hopefully somone has some advice for me. I just bought this bike about a month ago and its a bummer for it to break already.

Any help is appreciated, thanks,

kyle

--- End quote ---

So basically your engine is "locked up" when you try to kick your bike over? There is a possibility you are stuck  "between gears" from a broken shift shaft and or shift shaft spring. Like Gowen suggested, pull the clutch cover off and inspect the shifter mechanism. You can see it once you remove the clutch cover. If all looks good, sorry dude, but then your tranny has to come apart.

kx5tsi:
Looks like I lucked out on this one, as soon as the clutch cover came off, a 12mm bolt fell out. I guess somehow the bolt let loose and the star shaped thing attached to the end of the shift drum just fell off and lodged itself in there. It looks to still be in operational shape, with only one nick on the side that doesn't affect the gears themselves. Im going to put it back on, with a fair amount of loctite and reassemble, hopefully its my only problem.

 While I have it apart I pulled the clutch off to inspect the plates and they look almost new. My question is, how much torque need I apply to the bolts that hold the plate on and hold the disks in? Don't want to let one of those badboys fly around in there.

thanks,

kyle

Thanks,

kyle

kx5tsi:
Another question, it looks like the whole clutch housing needs to come off to be able to bolt this thing back up to the shift drum, and my problem is that the inside part is free spinning, as well as the outside part. What gives?

Whats the best way to get this thing off so I can see what im doin in there?

also if anyone knows the torque specs for the gear on the shift drum and for the giant nut holding the clutch case on i'd really appreciate it, hate to put it all back together and cause major damage because of a stupid bolt coming loose.

thanks,

kyle

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