Maintenance & Technical > KX500 Original

transmission issue

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greencannon:
the circlip that keeps 3rd gear in it's position on the output shaft folded over and broke for the second time. Upon inspection of the first teardown
 I noticed the area where the circlip contacts 3rd gear was severley worn, and the circlip was bent out of shape and resting in the bottom of the case. I replaced 3rd gear and the circlip along with rest of circlips and shims on that shaft. I replaced the shift forks while I was in there also. I double checked the schematic to make sure I reassembled the shaft in the proper order. Worked great for about a half a season then right in the middle of a ride,Zing !!!! 3rd turned into neutral.Just like it did the first time. The tranny used to be bullet-proof  until now.
Any ideas ??? 

500freak:
its probably because the area where the clip goes is worn out. i assume that where the clip fits is lose and after some abuse it falls off.

greencannon:
Good point, but the shaft is fairly new and the circlip seemed to snap in tight. Is there some kind of spec. to measure there ??
Any Experts ???

500freak:
does it have any side to side play? thats probably why it bends all up before it breaks off.

greencannon:
Like I   said it snaps in pretty tight. I'm thinking it would be almost impossible to not have a tiny amount of side play.

Calling on any experts ????

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