Maintenance & Technical > KX500 Original

Trans problem

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KXcam22:
KX5tsi,
  Grinding the dogs isn't very hard. If you have ported heads then no probs. The only tricky thing is to match them, ie. grind the same amount of each. There is usually 3 or 4 dogs on each gear so after you grind one whole gear you need to slip it on the shaft with its unground mating gear and use a feeler guage to check dog contact clearance. Then use a file to bring down the highest one so they all contact about the same (no clearance).  I used to race Husquvarnas in the old days. Got really good at fixing gears.  As for the shift forks, look at the wear patterns on each side.  A bent one will have obviously uneven wear. Hope this helps. Cam.

kx5tsi:
Thanks, hopefully I can repair it myself.

My bikes head is not ported to my knowledge, the only experience I have in porting is car cylinder heads, exhaust manifolds, intake manifolds etc.

Only mods to the bike that I am aware of are the pro circuit pipe and answer silencer, haven't pulled the motor apart yet so Im not really sure if thats the extent of it.

but thanks for the help, looks like I will have some time this weekend to rip it apart. I guess I'll find out whats really wrong.

kyle

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