Maintenance & Technical > KX500 Original

Tranny shift issues

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kxraptor:
My partner has a '01kx500 that he purchased used .The trans will not upshift at any rpm above idle.Downshift is fine.While upshifting alot more than normal effort is needed on the shift lever.We have had the bike in a reptuable shop and they have dis-assembled and inspected the trans and clutch .Everything was found to be straight with  no binding or wear on any gears,shafts or shift components.The only thing we can figure is possibly some mis-aligned cases.Possibly from the 1st owner damaging a case and replacing just the damaged half.Does this sound possible?Any other ideas are welcomed.

Hillclimb#42:
No idea really, especially since its been apart and back together and still doing it. Have you had the clutch cover off and watched everything operating, while shifting it. On a stand may be the way to look at it so you can roll the wheel. I'm certain, I am just tossing out ideas that you have done, and no insult to intelligence intended, just hoping a fresh view inspires a solution. Its wierd how a new perspective can solve a riddle like this sometimes.

kxraptor:
No we havent done that,,,I havent split cases personally,but had a very reputable bike mechanic do it.He did replace some items,,,shift forks and a gear or 2 that he felt were questionable.But to no avail.Almost everything on the clutch side has been replaced ,so I dont think its problem is there.

Hillclimb#42:
I have had a few tranny problems. Not the same symptoms, but when I had my yz125 stuck in gear, and another time had my kx250 stuck in neutral, I was able to see the issue while the cover was off. Its possible to have something assembled wrong just like it was before, if your mechanic is a visual learner and just put things back as he found them.
  Does it shift from neutral once and then hard to shift? There is a flat metal slider-deal in there that actually rotates the drum. if that deal doesn't return properly it causes issues. Also, if the drum makes an incomplete rotation, the next shift hits a corner of the drum, ect. ... that could lead you to what it's not, for sure. Someone will need to visually inspect the operation, to get to the bottom of it. Hope you didn't pay much to get it back in the same condition...

livenlife699:
Could be a bad shift fork, The engine I just had built had all 3 shift forks bent and a bad 3rd gear which I replaced it all and is perfect now...Split the cases and pull the tranny theres not much to them.

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