Maintenance & Technical > KX500 Original

'90 KX5 missing shifts

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NZ500:
Took it for a test ride today, definately has issues (I bent the gear lever away from ignition cover and wanted to see if that stopped it).

Pulled cover off and clicked up gears. When shifting up into third this is what it's looking like.... the wee roller isn't clicking into the slot all the way. I'm going to go keep working on it but if there's anything that looks obvious please let me know.

NZ500:
It feels like there's something inside (bent shift fork?) stopping it go further that there because I can't turn that gear selector from the outside to it clicks into third gear. It was in the groove in second gear.

I have done about 150-200km riding without this issue after rebuilding the motor. I'm thinking I might have forced it into gear at some stage and bent a shift fork?

Goat:
It sounds like 1 of 2 things to me. Both have to do with the shift fork. Could be bent or the pin that rides in the shift drum is marred up, bent, miss aligned, ect. ect.

Have you split the cases yet?

How did they lengthen the clutch rod? Seems pretty silly for an easy fix that isn't very expensive.

NZ500:
Hi Goat. I haven't had a chance to split the cases yet because I've got quite a few other jobs to do.

There was signs of weld on the side of the pushrod. No idea why I guess they were just tight/broke. The arm (clutch detent? I think they call it?) that pushes the rod was absolutely stuffed and had been welded up before to get some more life out of it too. Factory parts for any thing here (New Zealand) are a rip off compared to America and they're rarely in stock so I guess people are more likely to make do. The rod is over 1mm shorter than stock now but I guess that doesn't matter so long as it's doing what it is supposed to do.

Will repost when I've got motor apart. Might be a while now though.

NZ500:
Pulled motor apart today. Found the shift drum has a chip out of it (see pic). Yeah, the dowels/pins on each shift fork are worn past service limit too. One especially from going over top of that chipped piece. Going by the wear marks the pins don't sit in the drum very far? looks like they're only half way into the groove. Is this normal? Doesn't look like there's anything I can do about it though.

Have just ordered a heap of parts including 3 shift forks and the shift drum assembly among other things. I'm sure I could fix it but I really don't want to pull this thing apart again.

Also included a pic of a couple shafts I made today that bolt to a puller (which I also made) for splitting the cases. It worked really well. I thought it would have taken a lot more to get apart than that (was worried about using only two m6 aluminium threads at first). Didn't need it last time because bearing journals were worn out and it just tapped apart.


Edit: can't upload pics because it says upload folder is full

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