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Transmission problem with my kx125!

9K views 3 replies 2 participants last post by  6thWide  
#1 ·
So the other day my 03 kx125 had a problem. I dropped it very easily on the kickstarter side after realizing I couldnt make a climb I was attempting. When I wheeled it to the bottom of the hill, it started right up, but would go into 1st, then up to neutral, but nothing higher. I'm assuming its the shift fork, but I am undecided whether or not I should attempt the fix by myself, (I work as a small engine mechanic, but never messed with bike trannys) or if I should just tear it apart and send it to a pro. While the bike is apart Im going to put in new clutch plates, and rings. Does anybody know of a good transmission mechanic in NY. Specifically in the general area of Middletown NY? I would hate to send it to a dealer, because most of the local dealers arent very good at all. Any input would be great! Thanks in advance
 
#2 · (Edited)
it is your shift fork. the chances of something acctualy being wrong with your transmission gears or anything in that area is very low, unless you race the baja 1000. that drop could have been enough to knock it off. the best tranny mechanic around for this job is you yourself. it only takes removing the right side engine cover and maybe your clutch basket so you can get at it all easyer. to get the basket off take out the bolts with the springs, make sure the bike is in gear, and use an impact gun to take off the nut on the basket. leave the plates and such intact and in place becasue they offer the resistance you need to take off the basket nut. after that everything will come off easy there is nothing pressed on, it all just slides together nice and easy to where it came from. but do note the order in which washers and bolts and a small flat round bearings are throughout the entire removal of the clutch basket.
some washers and the metal pin that is used to opperate the clutch will look like its attached to the plate with the springs and bolts going through (yeah i forgot all the names of the parts. when i do it myself im just like "ok and now this thing and then this thing and last, this thing" lol i dont rembmber the real names). but their not attached. the oil makes a suction seal so it sticks a little. i tell you this so you dont put it down and it ends up getting knocked over and everything that you thought was one peice flys everywhere and you dont know how it was.
the shift fork can confuse you. it looks like it could work fine this way but it dosnt. then you think it looks like it works this way and it dosnt. and the way the spring is placed on the fork can confuse you as well becasue you didnt see it when it was right so you have to guess and check.
if i remember right and i think i do the fork looks like a C at the end around the pegs on a round plate that i always asscoiated with looking like a sugar cookie and made me want one.. lol yeah i kno... there should be two pegs inside the C at the end of the fork. and make sure the little wheel on the fork is riding along the bumps around the plate with the pegs. the bumps are all the same except a smaller bump on one of the bigger bumps. that small bump is the neutral gear.
it might be easyer to buy a service manual and it will tell you EVERYTHING you need to do along with pics of what the correct way is. and when the rightside engine cover is off check to see if the extruded metal "T" that pushes against the shiftfork is damaged, which could have caused it to derail, but probly didnt.
dont be intimidated by this job. its really simple and is good experiance for an unexperianced dirtbike mechanic. i see i caught you three days after you posted i hope you didnt give up and give it to a shop. good luck
 
#3 ·
thanks for the reply. Nope I havent sent it to a shop yet, its still in my garage waiting to be further looked at. I guess I'll Pull the clutch basket off and take a peek. We saw that wheel with the bumps and I thought maybe that was knocked one further out of sync than it should have been. The guy I bought the bike from said he was willing to come down and take a look at it to help me out. I do have one question for you though, After I pulled the right side covers off, this little pin fell out. It looks like its a pin from a roller bearing. That really scared me, because the only roller bearing is on the crankshaft. And it looks like my clutch basket was rubbing on the outside cover, what could the problem be there? Thanks again
 
#4 · (Edited)
the pin is for proper lineup when you instal the engine cover onto the case. look at the gasket surface either on the kickstarter side or the waterpump side and you will see a little hole that the pin will slide right into. sometimes they fall out durring removal. make sure you are positive about the clutch basket hitting the clutch cover. were there any metal shavings in the oil? or was the oil sparkly when you took it out? if it is then that means there was grinding. the only thing i can think of that would cause that to happen is a loose basket... which would have made a horrible sound while running the bike, and would have skipped the gears off eachother. in which case anyone would instantly recognise something was very wrong and shut it off. also check the plate thats held on by the bolts with springs around them, and the top of thoes bolts. but regardless, as long as you put it all together tight then there should be no problem at all. double check the clutch cover and the basket for signs of grinding against eachother. if you dumped the cover on something you could have punched it in a little to where it would hit the basket. i have done that before as well. the covers are around $30. inspect the teeth on the basket too. if there are grooves in them then that would cause your clutch to not disengage becasue the plates cant spread while stuck in thoes grooves. if their bad then you can try to file them down carefuly and evenly and at parallel to the teeth on the carbon plates. or you can buy a new basket for like $200