2018 KTM 150 SX not shifting

Chris Boothe 27
Hi. I recently had a rock hit my inner clutch cover which resulted in oil spilling out. I noticed it when it was still coming out, so I didn’t run it long without oil. At this time it would not shift gears, but it clicks as if it does shift. I took apart the transmission and didn’t notice any damage to any parts. I put it back together with everything to spec per the KTM shop manual. It is still doing the same thing. It clicks, but doesn’t actually shift. I replaced the clutch when putting a new clutch cover on it, but everything else remained the same. Has anyone else had this issue or have any idea of what may cause it? Thanks.
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hypermoto
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hypermoto 12/27/2020 8:38am
12/27/2020 8:38am Edited Date/Time 12/27/2020 8:41am
If it ran long enough without oil to stop shifting, you did not catch it early. They will run an impressive amount of time with no oil.

You need to split the cases again, and start measuring parts, looking for signs of excessive heat, warpage, etc. There will be some parts that are fine but a lot will need replacement.

Did you check if it rotated freely before putting cases back together? This will help closer identify the issue.
Chris Boothe 27 12/27/2020 9:21am
12/27/2020 9:21am
I only rode 2 laps and it still had at least 1/4 of the oil in it when I got off the track. At most if it happened right when I got on the track it was 2-3 minutes. Everything moves freely. The coolant was still completely full, so it couldn’t have gotten all that hot.
hypermoto
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hypermoto 12/27/2020 10:08am
12/27/2020 10:08am
Chris Boothe 27 wrote:
I only rode 2 laps and it still had at least 1/4 of the oil in it when I got off the track. At most if...
I only rode 2 laps and it still had at least 1/4 of the oil in it when I got off the track. At most if it happened right when I got on the track it was 2-3 minutes. Everything moves freely. The coolant was still completely full, so it couldn’t have gotten all that hot.
Depending where the rock hit, 1/4 oil could have been below the crack, and only leaked out slightly while it was swooshing around. It’s a 2 stroke so coolant level being normal is normal since it was a transmission issue. The gears would get hot very quick, but would take a very long time to affect coolant consumption. The tranny would lock up well before that in a 2 stroke.

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garagedog
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garagedog 12/27/2020 10:16am
12/27/2020 10:16am Edited Date/Time 12/27/2020 10:18am
Pull the right engine cover and check the shifting mech. Maybe something got bent or cracked on that impact. Look at parts 1-6, 12-16, 25, 26 carefully. Go through the gears and roll the rear wheel a little as you do it to make sure each gear engages. You can see it move properly by watching parts 14 and 26 working together as it goes through each gear. The little half notch between 1st and 2nd is the neutral position.

https://www.ktmpartspro.com/oemparts/a/ktm/59b17f8ceb0bed83303bef59/shi…
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