Maintenance & Technical > KX500 Original

transmission issue

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Goat:
It may not be the clip or the groove it fits into. Is there any slop to the gear itself? It may be moving around enough to bend the clip to the point of breaking. Also how are the other gears. Maybe when you change to third the opposing gear it comes in contact with is not aligning correctly and causing binding therefore putting too much stress on the clip and it fails and breaks off? Been thinking about this odd problem since you posted. Not an expert but I do like to figure out odd problems :)

fluffy:
on page 11 figure 21 of your clymer kx manual it showes the correct way to install the clip. hope this helps.

BDI:
If the problem was being caused by to much side force you may not have fixed the whole problem. I like to treat trans problems like a group of bad chrildren, rather then play the who did what game, you just go ahead and spank them all that way you know you get the right one. If the dogs on the gear were bad causing the gear to want to push away from the other gear it was ingaged with, this could possibly create enough side force to cause the clip to fail. Now if you have a gear with bad dogs on it, the gear that it ingages will also have bad dogs and will also need to be replaced or the problem will come back. Gears that like to pop out of mesh will seldom show any significant signes of damage. Typicaly the dogs will only be slightly rounded on the edge, to someone that does not know any better they will look just fine. Also you should be carefull when asking for an expert to answer your question,(1) you are probably going to hurt the fealings of anyone that has tried to help thus far (2) you would have to be a little if not very arrogant to answer a post where an expert has been called upon, even if you were an expert.

DoldGuy:
Thats why we have you BDI  :-D

greencannon:
I couldn't help but crack a smile at that one BDI...
That's some good stuff there.  I'll be sure to thoroughly inspect all components again. You made me realize that I was instantly distracted by the obvious damage to the side of the gear. Thus causing me to forget about why it happened. 
1. I welcome anybody's input. No offenses here.
2. When a man assumes and looks for arrogance, he often finds it...

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