Bike stuck in 1st geat

R-acer
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R-acer
Edited Date/Time 1/27/2012 3:29pm
Ok guys... im not a transmission guy, went out with my son today with his 08 KTM144SX, bike was running great after a complete rebuild, but about 6 or so laps into practice, the bike got stuck in 1st. It wont go into neutral or and other gear.
Whats the problem?
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Void Main
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Void Main 4/18/2009 4:38pm
4/18/2009 4:38pm
That's the only gear he should need to beat his old man.
Void Main
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Void Main 4/18/2009 4:54pm
4/18/2009 4:54pm
#14:



Just go here and select your year/model and then "Shifting Mechanism":

http://www.ktmworld.com/ktm_oem_parts.asp

Looks like that is a fairly common issue when that happens (not necessarily on that exact bike). I don't know this first hand, only from searching the net.

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R-acer
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R-acer 4/18/2009 4:58pm
4/18/2009 4:58pm
Well this sounds like a guaranteed engine splitting repairAngry
tydog
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tydog 4/18/2009 5:00pm
4/18/2009 5:00pm
will the shifter move, either up or down?
Void Main
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Void Main 4/18/2009 5:02pm
4/18/2009 5:02pm
Maybe not. I think you can pull the shift shaft without splitting the cases. If you are lucky you might find the problem without having to tear it down completely.
R-acer
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R-acer 4/18/2009 5:04pm
4/18/2009 5:04pm
tydog wrote:
will the shifter move, either up or down?
Yes the shifter moves up no problem, but doesnt do anything... as if something slipped off or its not engaging or moving the gears.
xnationalwrench 4/18/2009 5:07pm
4/18/2009 5:07pm
Take a look at the adjuster srew (notice it says to use loctite) and check if it has backed off
Craze
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Craze 4/18/2009 5:28pm
4/18/2009 5:28pm
I would suspect part #10 (Shift rachet) It resembles the old Suzuki kick starter pall that would break and the lever would just move with no engagement
lumpy790
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lumpy790 4/18/2009 6:04pm
4/18/2009 6:04pm
I doubt it will require splitting the cases again.

Check #16 to see if its tight.
Sweendoggy18
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Sweendoggy18 4/18/2009 8:40pm
4/18/2009 8:40pm Edited Date/Time 4/18/2009 8:41pm
This happened to my cr250, and it was the return spring...part 14 on that photo...no splitting of the cases, just taking the clutch side cover off...no biggy
R-acer
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R-acer 4/18/2009 8:47pm
4/18/2009 8:47pm
I have the clutch out right now, but I dont have a tool big enough to pull the nut on the clutch basket. The clutch and basket looks fine, but I need to get behind it to see what the problem is. I will try and get the tool tomorrow
Sweendoggy18
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Sweendoggy18 4/18/2009 9:36pm
4/18/2009 9:36pm
ya thats the bad part, have to take the clutch basket off to get to it...
R-acer
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R-acer 4/18/2009 9:45pm
4/18/2009 9:45pm
Void Main wrote:
Don't you have a BMFH?
Since I dont even know what a BMFH is.... I dont think I have one lol
Void Main
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Void Main 4/18/2009 9:49pm
4/18/2009 9:49pm
Everyone should have a BMFH. Maybe they don't sell them in Canada?
Craze
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Craze 4/18/2009 10:55pm
4/18/2009 10:55pm Edited Date/Time 4/16/2016 11:27pm
Void Main wrote:
Don't you have a BMFH?
R-acer wrote:
Since I dont even know what a BMFH is.... I dont think I have one lol
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rmgsxr
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rmgsxr 4/18/2009 11:39pm
4/18/2009 11:39pm
lumpy790 wrote:
I doubt it will require splitting the cases again.

Check #16 to see if its tight.
#16 would be my guess. Have seen it many times.
kaw rider9
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kaw rider9 4/19/2009 7:56am
4/19/2009 7:56am
R-acer wrote:
I have the clutch out right now, but I dont have a tool big enough to pull the nut on the clutch basket. The clutch and...
I have the clutch out right now, but I dont have a tool big enough to pull the nut on the clutch basket. The clutch and basket looks fine, but I need to get behind it to see what the problem is. I will try and get the tool tomorrow
You're not a big enough tool?Wink

Cruise on down to my place, I'll let ya borrow what ya need!
R-acer
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R-acer 4/19/2009 7:32pm
4/19/2009 7:32pm Edited Date/Time 4/16/2016 11:28pm
I FIXED IT!!! It was #6, 7, 10 & 11 combo. The #6 spring and the little #7 cap was stuck down so the little tab/flap (#10) couldnt engage and turn #13. Woohoo
kaw rider9
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kaw rider9 4/19/2009 7:52pm
4/19/2009 7:52pm
R-acer wrote:
I FIXED IT!!! It was #6, 7, 10 & 11 combo. The #6 spring and the little #7 cap was stuck down so the little tab/flap...
I FIXED IT!!! It was #6, 7, 10 & 11 combo. The #6 spring and the little #7 cap was stuck down so the little tab/flap (#10) couldnt engage and turn #13. Woohoo
Good job!
R-acer
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R-acer 4/20/2009 5:31am
4/20/2009 5:31am
Void Main wrote:
Cool beans! Now the question is, what caused it?
That is the million dollar question. Not sure. There was fresh oil in the case and everything inside there is like brand spanking new. not even a wear mark on anything and not even a dirt grain on the bottom of the case.
I hope it doesnt happen again, it was a lot of work.
If it does happen again though, I will order new parts to go in there.
Cygnus
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Cygnus 4/20/2009 6:16am
4/20/2009 6:16am
Void Main wrote:
Cool beans! Now the question is, what caused it?
It's a KTM.
R-acer
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R-acer 4/20/2009 9:17am
4/20/2009 9:17am Edited Date/Time 4/16/2016 11:29pm
Void Main wrote:
Cool beans! Now the question is, what caused it?
Cygnus wrote:
It's a KTM.
I have to admit..when its running good, it kicks the shit out of everything else in its class, and even some out of its class. He spent the weekend on my YZ450F and handles it surprisinly well. I think he is converted to 4 strokes now that he had a tast of it.
When I told him last night that his bike was fixed..... he kinda paused (didnt look excited like I thought he would have) and said...ummm...I want to race your bike this weekendUnsure
Craze
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Craze 4/20/2009 5:24pm
4/20/2009 5:24pm
R-acer wrote:
I FIXED IT!!! It was #6, 7, 10 & 11 combo. The #6 spring and the little #7 cap was stuck down so the little tab/flap...
I FIXED IT!!! It was #6, 7, 10 & 11 combo. The #6 spring and the little #7 cap was stuck down so the little tab/flap (#10) couldnt engage and turn #13. Woohoo
I was pretty damn close in guessing....see my earlier post...LOL
R-acer
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R-acer 4/21/2009 4:22am
4/21/2009 4:22am
Craze wrote:
I would suspect part #10 (Shift rachet) It resembles the old Suzuki kick starter pall that would break and the lever would just move with no...
I would suspect part #10 (Shift rachet) It resembles the old Suzuki kick starter pall that would break and the lever would just move with no engagement
You were more than close!! Because the little cap and spring was stuck down, part #10 couldnt engage.... so I say you were right.
AMA714
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AMA714 4/21/2009 8:05am
4/21/2009 8:05am Edited Date/Time 4/21/2009 8:05am
hey R-acer, how do you like the YZ. A dealer here just made me a ridiculous offer to get me on a 2009 Limited YZ450 (white plastic)

I have been riding CRF450's sonce they came out so I dont have any experience with Yamaha.

sorry... thread jack

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