Maintenance & Technical > KX500 Original

'90 KX5 missing shifts

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NZ500:
Hey all. I've spent a huge amount of time rebuilding my KX500. I did about 4 hours on the fresh motor and the clutch started slipping. I put in a new full clutch kit and it started slipping again. Have sorted that today by shortening the rod (again!) that goes through motor. The motor is going well and clutch isn't slipping now, but it's not staying in gears when I shift up. Mostly going up into third I noticed it. It's like it's not 'clicking' into that gear. The bike will suddenly rev and probably do not so nice things to my gearbox.

Was supposed to be doing a big event in a couple of weeks but it really is flat out and I think I'll wreck it if I ride it like this.

Any ideas? Am I going to have to split the cases again and replace the shift forks? Maybe riding with clutch slipping has damaged something?

I hate this bike! lol

Polar-Bus:
1st question why are you "shortening the clutch rod" to rid the clutch slippage ? You definately have some type of incorrect assembly with your clutch. KX clutch systems are simple, and generally extremly reliable. All's your doing by shortening the rod is "band-aiding" the real issue. 2nd question did the tranny jump out of gears before your rebuild? We need much more details pre, and post rebuild.

NZ500:
Because the clutch rod was to long, causing the clutch not to clamp up properly. The original arm on the left side of motor was rooted and someone has lengthened the rod to compensate for that wear rather than fix the problem causing it. I replaced that arm with a new one when I rebuilt motor. That is why the rod is now to long. The original clutch looked (and measured) like new when I did rebuild so I didn't touch it. I rode it for about 4 hours and when it started slipping I put a new full clutch kit in it with heavy springs. They might have been reliable transmissions when they're new, but this bike is over 20 years old now and has done a hell of a lot of hours.

The bike never ran when I got it. It had a snapped kick starter shaft and then I found the motor was well overdue for rebuild (main bearings stuffed). Once rebuilt I rode it for a few hours before the clutch started slipping and although it wasn't very nice to shift compared to other newer bikes I've had it wasn't missing so bad (about as smooth as I'd expect a powerful bike of this age to shift).

I can still put the bike in gear with the clutch pulled in without it trying to take off or stall.

littlewing78:
I had a similar problem.  Might be the same might not. 
http://www.kxriders.com/forums/index.php/topic,9638.msg76078.html#msg76078

NZ500:

--- Quote from: littlewing78 on November 13, 2011, 06:27:07 AM ---I had a similar problem.  Might be the same might not. 
http://www.kxriders.com/forums/index.php/topic,9638.msg76078.html#msg76078

--- End quote ---

Thanks. That would be an easy fix. Maybe a spring has popped off when I had the cover off?

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