Author Topic: KTM shifting issue  (Read 2029 times)

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ajd187

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KTM shifting issue
« on: August 28, 2015, 01:19:20 pm »
during the 24 hour, at about 1:15 am, I suddenly only had gears 3-6 (I think), which I blamed on a loose shift lever (common KTM problem).  however, once I got back and tightened it, I noticed I only had the same amount of gears.

Figuring it was a broken clutch plate stuck somewhere, I brought it home and ordered a clutch kit (probably needs one anyway).  However when I took the clutch out it looked fine, minus a toasted inner steel plate.

New clutch is at home, but Im' guessing that won't fix the issue. 

Have any of you guys ever heard of this fix?  My symptoms sound erriily similar.
http://www.vitalmx.com/forums/Race-Shop,42/KTM-wont-shift-HELP,1258904

2007 KTM 200 XC-W #59

Jim Dettman

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Re: KTM shifting issue
« Reply #1 on: August 28, 2015, 01:50:50 pm »
No, a clutch won't effect just some of the gears.

It's either:

1. Shifting pawls.

2. Shifting fork is bent.

3. Problem with the gears.

  My guess #2, but hopefully you have a problem with #1.  That's under a case cover.   To fix #2 or #3, it means splitting the cases.

Jim.
2009 CRF250x /2009 CRF450x

ajd187

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KTM shifting issue
« Reply #2 on: August 28, 2015, 02:54:32 pm »
I've had it happen before. Plate broke and got stuck in shifting mechanism.  I was hoping for that. 

Thst mechanism in the link looks promising so I'm gonna try taht before splitting.
2007 KTM 200 XC-W #59

ajd187

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Re: KTM shifting issue
« Reply #3 on: August 28, 2015, 03:50:14 pm »
specficialy referring to this:
http://www.youtube.com/watch?v=Ruy7lxSf5CA
2007 KTM 200 XC-W #59

Jim Dettman

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Re: KTM shifting issue
« Reply #4 on: August 28, 2015, 04:18:19 pm »
 Yes, the jap bikes all use a similar design; shifter is connected to a pawl/ratchet assembly, which turns a drum, which two shifter forks slide up and down on.  The fork ends are what actually move the gears on the shafts.

 So hopefully your problem is with the pawl/ratchet assembly.  I doubt you'd have a bunch of gears go at once, so that leaves a bent shifter fork as the only other thing.

Jim.

 
2009 CRF250x /2009 CRF450x

Brenden

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Re: KTM shifting issue
« Reply #5 on: August 29, 2015, 03:52:15 pm »
take the side case off and the clutch off and youll be able to see the shift mechanism pretty easy.

ajd187

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Re: KTM shifting issue
« Reply #6 on: August 29, 2015, 07:29:49 pm »
take the side case off and the clutch off and youll be able to see the shift mechanism pretty easy.
Yeah that's my next step once I have time to mess with it some more.

Shift forks looks easy enough. It's just all the other work to get there that's the pain.

However I think it's that mechanism in the video. Then again the bike has 115 hours so anything is possible.
2007 KTM 200 XC-W #59

ajd187

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KTM shifting issue
« Reply #7 on: August 29, 2015, 10:10:07 pm »
So I just put in my new clutch pack and put thr stock ktm shifter back on. 

Tightened everything up,  tried shifter. Seemed to work. Hmm.  Found neutral. Pulled out in my driveway and ran it up and down a few times.

All seems ok now. I'm just not sure why?  Nothing was broken and only one steel, the most inner one,  was burned.
2007 KTM 200 XC-W #59

redrider911

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Re: KTM shifting issue
« Reply #8 on: August 30, 2015, 01:52:54 am »
What the hell do you do with your clutch? Haha
"I swear, some chicks around here look like they fell face first into a tackle box on their way to or from the IHOP."
- Trail Ryder

mirageags

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Re: KTM shifting issue
« Reply #9 on: August 30, 2015, 09:07:28 am »
I was trying to figure that out myself. The open part of that course is shift and go on the two stroke. The rutted woods were nasty but i can only remember getting a little bit of clutch fade at night.
You should buy stock in a clutch company
2017 KTM 250 EXC-F
1983 KTM 250 MXC
2005 Yamaha TTR 125L
2009 Suzuki Boulevard M50 (vz800)
2008 Honda TRX250EX ( wifes)
1988 yamaha razz 50 scooter

ajd187

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Re: KTM shifting issue
« Reply #10 on: August 30, 2015, 11:23:47 am »
I was trying to figure that out myself. The open part of that course is shift and go on the two stroke. The rutted woods were nasty but i can only remember getting a little bit of clutch fade at night.
You should buy stock in a clutch company
What about if you stall your bike on a shale Hill and have to start it in whatever gear you have left and ride the rest of the way back like that?

I have stock in DP but that's something else.... Haha

Sent from my SM-G900V using Tapatalk

2007 KTM 200 XC-W #59

mirageags

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Re: KTM shifting issue
« Reply #11 on: August 30, 2015, 12:48:34 pm »
Andrew will shortly chime in to tell you that it trahes you to be faster. Lol
2017 KTM 250 EXC-F
1983 KTM 250 MXC
2005 Yamaha TTR 125L
2009 Suzuki Boulevard M50 (vz800)
2008 Honda TRX250EX ( wifes)
1988 yamaha razz 50 scooter

ajd187

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KTM shifting issue
« Reply #12 on: August 30, 2015, 08:02:32 pm »
Haha.

I looked everytbjng over closely again tonight.  I think the problem was actually the lever. The inside of it where it goes on the shaft was pretty boogered up. 

On a Japanese bike this is a non issue because you will catch it and replace the lever. But this Hammerhead one would seem fine with a retightening.  Until it didn't work.
2007 KTM 200 XC-W #59

mirageags

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Re: KTM shifting issue
« Reply #13 on: August 30, 2015, 08:30:52 pm »
The clutch plate blued probobly overheating it trying to get it going in 3rd
2017 KTM 250 EXC-F
1983 KTM 250 MXC
2005 Yamaha TTR 125L
2009 Suzuki Boulevard M50 (vz800)
2008 Honda TRX250EX ( wifes)
1988 yamaha razz 50 scooter

Brenden

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Re: KTM shifting issue
« Reply #14 on: August 30, 2015, 09:38:08 pm »
I love the ktm shifter design.  instead of replacing a wappered out lever every year, I can go many years on the same lever.  Red loc tight on the bolt and some silicone on the splines keeps the shifter from loosening.