Transmission problems 2004 KX125

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BKoonts

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4/25/2011 8:46 AM

I have a 2004 KX125 and every time I change the oil it takes me about 1/2 hour to get the bike to switch through the gears. At first it's stuck in neutral. I can get it into 1st gear and then it takes about 5 minutes to get it into second, going back and forth between 1st and neutral. This process continues for all of the gears. The strange thing is that once I can get the bike through all gears cleanly the bike shifts perfectly. Does anyone have any thoughts as to what might be causing this? I haven't inspected the plates or anything yet. Thanks

lumpy790

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4/25/2011 9:19 AM

You bike is possessed! Call a Priest now!

mxb2

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4/25/2011 10:40 AM

its 7 years old, get a new 250f!

xnationalwrench

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4/25/2011 12:32 PM

Pull the clutch cover off and inspect the clutch plates and then the basket, then in the shift mechanism check the flapper along with the pin and spring.

motofab36

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4/25/2011 3:17 PM

The drain plug bolt is stretched. Get a new bolt and washer, in fact buy a couple bolts so you have a spare. The bolts stretch as you reuse them several times. on the kx 125 the bolt threads in directly below the shift drum. It is a very close fit even with a new bolt and as the bolt stretches slightly it rubs on the shift drum.

mx5471

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4/25/2011 8:22 PM
Edited Date/Time: 4/25/2011 8:30 PM

Motofab36. I'm impressed. I've been a mechanic for years,and I always say ,the first thing to do when diagnosing a problem is to try the easiest thing first. Just to eliminate it before digging in deeper. But I never would have thought of that in a million years.The other thing I say is that there is no better thing than experience.If you're right about that bolt,you just saved that gentleman countless hours of aggravation ,and expense. With your permission,(if you will), I'm just going to add one thing. Change your oil,throw another washer or 2 on the bolt and tighten it. If it drips a little don't worry about it. Go ride it,and see if the shifting is good. That will tell you if the bolt is causing a problem. I never had Kawi's but I have experienced the same problem with bolts that motofab36 has on Yamaha's,but in different areas.I still don't understand how it happens. A steel bolt threading into an aluminum casting,and the bolt has the failure,not the casting. I've had it happen on every Yamaha 4 stroke we had. Maybe someone can explain it to me.

motofab36

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4/26/2011 6:06 AM

LOL, I learned the hard way. I had a customer bring in a kx 125 with the same problem. After looking at everything else, even splitting the cases a couple times I saw what the problem was. Sometimes its easy to look past the simple things. I've seen several stretched drain bolts. You'll see it just below the head of the bolt.

BKoonts

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4/26/2011 9:01 AM

Wow. That was not the troubleshooting advice that I was expecting to hear. I have never heard of anything like that happening before. That is exactly why it's 100% worth it to post a question. I would have had the cases split in no time trying to figure out what the hell is wrong with this thing. I haven't swapped the plug out yet but it seems like this will be the solution. Thanks very much for taking the time to read my question and get back to me with a response.

OldTiddler

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4/26/2011 2:37 PM

If motofab's suggestion ends up fixing it, he deserves a case of beer or something.

motofab36

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4/29/2011 2:35 PM

Well did that fix it? If so, Coors Light please

Kawasaki 89

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11/5/2012 12:37 PM

Brilliant my mates 04 kx 125 had this problem after changing the oil

It would not click into gear and felt jammed after reading this we went and loosened the oil drain bolt and bam it went straight into gear

Brilliant thanks

motofab36

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11/5/2012 4:15 PM

Kawasaki 89 wrote:

Brilliant my mates 04 kx 125 had this problem after changing the oil

It would not click into gear and felt jammed after reading this we went and loosened the oil drain bolt and bam it went straight into gear

Brilliant thanks

MOTODAD422

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11/6/2012 10:22 AM

Had the same problem , use 2 drain plug washers, or grind a little bit of of the drain plug.

2strokekenny

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3/16/2015 6:45 AM

So does it work ? Lol my 2004 is doing the same it dident want to shift out of second gear then finally got it to shift and worked great ?

mimafia

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3/17/2015 2:14 PM

motofab36 wrote:

The drain plug bolt is stretched. Get a new bolt and washer, in fact buy a couple bolts so you have a spare. The bolts stretch as you reuse them several times. on the kx 125 the bolt threads in directly below the shift drum. It is a very close fit even with a new bolt and as the bolt stretches slightly it rubs on the shift drum.

Had the same thing happen. I bet this is the fix! Who knew it would be so easy lol. I sure didn't. When I compared my stretched one to the new one it was significantly longer.

garagedog

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3/17/2015 3:09 PM

Best thread I've read in months. Thanks!

Camber75

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3/17/2015 4:41 PM
Edited Date/Time: 3/17/2015 4:43 PM

You beat me to it, was going to suggest the same thing!! I also see now this is a very old thread!

2strokekenny

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3/18/2015 2:39 PM

Camber75 wrote:

You beat me to it, was going to suggest the same thing!! I also see now this is a very old thread!

So it works lol ?