Two Stroke Motocross
Two Stroke Motocross Forum => General Two Stroke Talk => Topic started by: westhall55 on March 23, 2013, 03:56:18 AM
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I have a 2001 Kx 250 that I am having issues with... I was riding one day and it wouldn't shift out of second gear. So I opened the clutch and took basket out. Looks like the spring keeps popping off. So I replaced the spring and put it back together. Rode for about 10 mins and did the same thing. For some reason the spring keeps popping off. The one that brings the shifter back to the center. I'm thinking about and and when I put the inner clutch cover back on the tab that sticks out of the case that the shifter butts up to looks like it has been filed down and the is to much play between the end of the shifter and case. Almost 1/4 inch probably! Is this normal? I wouldn't think so! But I know for sure someone has grinded that tab down. Does anyone know if the tab is suppose to be up level with the side of the inner case? Thanks so much guys
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Sounds like it might be worn out, from years if the shifter rubbing on it. Maybe a little weld on it then file it down or something might be an easy fix
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Would jb weld weld be strong enough? I guess just dril three small little holes in it and it would hold better?
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It's a simple job to tig weld the worn part. What usually happens with the JB weld is it eventually flakes off and jambs up the shift drum.
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How would you tig weld it? Isn't it pot metal? If it was aluminum I could see it but maybe it is aluminum... I could probably take it to a welding shop huh? Thanks
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Take it to a welding/machine shop and see what they can do. Odds are they can tig it real easy, then grind it down to shape, good as new.
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Okay took it all apart and here is the problem i think! The shift shaft can move horizontally through the case and is suppose to be held in place by the tab shown in below pics. The tab on inner case has been ground down in fashion (looks to be man made) i would say almost 1/3 inch. When i opened it up i found the little spring that holds the fork and the shaft laying in the bottom and spring was all bent up and sheared. So i know im losing shifting from the spring being sheared off.
Now... I moved the shaft all the way out and the little tab that the spring goes through hits the kickstarting gear. So i think what is happening is the tab on the inner case that is ground down is letting the shaft move to far over and the spring is getting sheared off by the kickstarter gear! What do yall think? Is there suppose to be this much space between tab and shift shaft?
Thanks alot for all the help!!!
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And btw never go to Gainesville Motorsports in Gainesville,Ga. As you can see they told me all new gaskets were placed throughout and they used Gasket Sealer! They have already gotten the phone call!grrrr
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There might be a way to "McGyver" this for a short term fix until you can weld/replace the case: just put a plastic tube over the shift shaft between the shift lever and the side case to prevent lateral play.
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Here could be another DIY way to do this without spending a lot of money. The only challenge would be matching the contour of the case side using a dremmel or other semi precise metal grinder. But, you could take a wrist pin from an old piston that would fit over that worn metal tab and cut it to the measurement of the longer side of the case. Than, shape it as near as you can with a grinder. This would prevent lateral play like Sachs said, but it would be the next best thing to a permanent fix in my opinion to welding it.
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The cost of any repairs will be the cost of just buying a new case piece off ebay.
I know which one is less of a headache
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http://www.ebay.com/itm/KX250-KAWASAKI-2000-KX-250-00-LOT-C-INNER-CLUTCH-COVER-/110941478521?pt=Motorcycles_Parts_Accessories&hash=item19d4a09e79&vxp=mtr