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KX60 shifting issue

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Coop:
As some of you know, I completely rebuilt a KX60 for my nephew Nick. On the bench during re-assembly it shifted perfectly. On the first ride last week it would only shift past second if I pushed down slightly on the shifter and then shifted back up. Doing that it shifted through all the gears. I suspected a return spring problem so I pulled the clutch cover, pulled the clutch and completely re-installed the shift shaft, return spring, shifter mechanism, selector mechanism, etc. Now it won't shift past second at all, LOL. Shifting from first to neutral to second, and back down again is smooth as silk. But try to shift up from second and it's like you are in top gear.

It seems weird it would be a shift fork problem since it was basically working before I unassembled and reassembled the above mentioned parts. I am thinking maybe I botched something up. Any ideas? Tomorrow I plan to tear back into it but it's driving me nuts thinking about it and I was hoping for some ideas  :-D .

BDI:
Maybe you didn't get the shift forks in there right.

Coop:

--- Quote from: BDI on July 18, 2010, 01:55:00 PM ---Maybe you didn't get the shift forks in there right.

--- End quote ---

Yeah I am starting to think I will be re-splitting the cases this week to see what the heck is going on if once I check the shifting mechanisms under the clutch cover one more time. I have too much time in it now to half-ass anything. It just seems weird to me that would be a fork because it was working and the bike only has had one slow short ride around my yard. But I am not ruling anything out.

jonny500:
you didnt say if the engine was running or not. in my experience some gear boxs just like to be run a bit before they start shifting smoothly. i think its just everything settling in. i had a kx 250 that i rebiult before weston beach race. when i was running it in it would not go out of second, i started to panic as is was the day before race day. i just rode up and down the beach gently trying to shift in to 3rd and it just went after  while and  the bike was perfect. of course there is a chance you have put it in wrong. but before striping i would just try that, i have poped some pics in from a site i know hope they help
best regards and good luck
john

jonny500:
pic 2

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