2018 KTM 450SX-F FE No Shift Past 2nd

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12/8/2018 8:19 AM

Bikes rolls 40 hrs while warming up on the stand. 2nd lap of practice bike will not shift past 2nd. The 1-2 shift is fine. Any suggestions? Fuel pump first now this....

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2020 YZ450F
2018 KTM 450SXF FE
2016 YZ250F 2008 CRF450R
2015 YZ250F 2008 CRF250R
2001 CR250R
2010 YZ250 2012 CRF150R
2009 YZ125 2010 KX109.5
SSR Motorsports Dealer YCF Motorcycles
TAGMX Suspension & Graphics! www.tagmxsuspension.com https://www.liquidskinzdesign.com/



12/8/2018 8:30 AM

Should have listened to me in the last thread.! Hopefully it's just something in the shift mechanism. I would be looking for metal in the oil and filter.

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12/8/2018 9:29 AM

Drop 3 teeth off rear sprocket and leave it in 2nd. That engines so usable u dont need anything else.

Sorry no worthwhile input. Maybe shifter adjusted too high and is hitting.

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12/8/2018 9:40 AM

Hopefully just the shift mechanism and not a bent shift fork

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12/8/2018 9:59 AM

Not sure if this will help any but I was able to get it to go up to 4th a couple of times but had to really jiggle the shifter to get it to go 2 to 3 to 4 and same going back from 4 to 3 to 2. Again the 1-2 shift is fine.

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2020 YZ450F
2018 KTM 450SXF FE
2016 YZ250F 2008 CRF450R
2015 YZ250F 2008 CRF250R
2001 CR250R
2010 YZ250 2012 CRF150R
2009 YZ125 2010 KX109.5
SSR Motorsports Dealer YCF Motorcycles
TAGMX Suspension & Graphics! www.tagmxsuspension.com https://www.liquidskinzdesign.com/



12/8/2018 11:24 AM
Edited Date/Time: 12/8/2018 11:27 AM

Photo

Had this happen on a few KTMs. The part #11 Sliding plate is bypassing the shifting drum. The tension spring could be broke #9 to cause this or the teeth are dull and not getting a good connection/hook on the drum. If your spring is ok, you can take a small round file and sharpen the teeth on the sliding plate.

The file you use needs to mach the diameter of the round shifting points on the drum. Like 3/16

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12/8/2018 11:34 AM

Geez you have some bad luck, the Yamaha 250 issues and this bike.

Hoping you find a solution!

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12/8/2018 11:39 AM

Lynch wrote:

Geez you have some bad luck, the Yamaha 250 issues and this bike.

Hoping you find a solution!

I appreciate it. My son rides a lot. The yamaha was simple once we figured out it was a the TPS, put another 140+ hours on it problem free! Matter fact it has been completely rebuilt with a carrillo rod and a JE piston!

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2020 YZ450F
2018 KTM 450SXF FE
2016 YZ250F 2008 CRF450R
2015 YZ250F 2008 CRF250R
2001 CR250R
2010 YZ250 2012 CRF150R
2009 YZ125 2010 KX109.5
SSR Motorsports Dealer YCF Motorcycles
TAGMX Suspension & Graphics! www.tagmxsuspension.com https://www.liquidskinzdesign.com/



12/8/2018 12:04 PM

Here a possibility

Photo
photo credit to Cudby, sketch credit to brimx153

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12/8/2018 12:15 PM

fullfloater wrote:

Here a possibility

Photo
photo credit to Cudby, sketch credit to brimx153

You are a brave man posting that without permission.

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12/8/2018 1:48 PM

Markee wrote: Photo

Had this happen on a few KTMs. The part #11 Sliding plate is bypassing the shifting drum. The tension spring could be broke ...more

I had hard shifting in a KTM 250 2steoke.... Stretching by hand part n 9 (the spring) solved the issue. Don't know if it helps or could be related

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12/8/2018 2:40 PM

Markee wrote: Photo

Had this happen on a few KTMs. The part #11 Sliding plate is bypassing the shifting drum. The tension spring could be broke ...more

Also check that bolts numbered 18 and 21 (not shown in this part of the shift mechanism parts page) have not come loose. Clutch basket has to come out to do though. Have seen that before where someone skipped the loctite application.

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12/9/2018 1:13 AM

Markee wrote: Photo

Had this happen on a few KTMs. The part #11 Sliding plate is bypassing the shifting drum. The tension spring could be broke ...more
Underground wrote:

Also check that bolts numbered 18 and 21 (not shown in this part of the shift mechanism parts page) have not come loose. ...more

That sounds like what the dealer told me to check. I called them and ask if they had any suggestions. They told me to pull the basket out and check a bolt but lost me after that. I will be honest, I do not do anything inside a motor lol, so I will have one of our techs look at this next week. I appreciate the input guys, I sure hope it is as simple as this!!!

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2020 YZ450F
2018 KTM 450SXF FE
2016 YZ250F 2008 CRF450R
2015 YZ250F 2008 CRF250R
2001 CR250R
2010 YZ250 2012 CRF150R
2009 YZ125 2010 KX109.5
SSR Motorsports Dealer YCF Motorcycles
TAGMX Suspension & Graphics! www.tagmxsuspension.com https://www.liquidskinzdesign.com/



12/14/2018 8:46 AM

Good news good news, it was part #18 was loose! A little lock tite and a ordering a new gasket to be safe! Thanks so much for the help Vital!!!

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2020 YZ450F
2018 KTM 450SXF FE
2016 YZ250F 2008 CRF450R
2015 YZ250F 2008 CRF250R
2001 CR250R
2010 YZ250 2012 CRF150R
2009 YZ125 2010 KX109.5
SSR Motorsports Dealer YCF Motorcycles
TAGMX Suspension & Graphics! www.tagmxsuspension.com https://www.liquidskinzdesign.com/



12/14/2018 11:33 AM

sgrimmxdad wrote:

Good news good news, it was part #18 was loose! A little lock tite and a ordering a new gasket to be safe! Thanks so much for ...more

Good deal

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1/7/2019 2:33 PM

sgrimmxdad wrote:

Good news good news, it was part #18 was loose! A little lock tite and a ordering a new gasket to be safe! Thanks so much for ...more

Same exact problem with a 2018 450 XCF

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1/7/2019 3:00 PM

They're buying new factories with the savings on loctite

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1/8/2019 1:21 AM

sgrimmxdad wrote:

Good news good news, it was part #18 was loose! A little lock tite and a ordering a new gasket to be safe! Thanks so much for ...more

DaveJ wrote:

Same exact problem with a 2018 450 XCF

Have you fixed it yet? Wondering if the same problem!

|

2020 YZ450F
2018 KTM 450SXF FE
2016 YZ250F 2008 CRF450R
2015 YZ250F 2008 CRF250R
2001 CR250R
2010 YZ250 2012 CRF150R
2009 YZ125 2010 KX109.5
SSR Motorsports Dealer YCF Motorcycles
TAGMX Suspension & Graphics! www.tagmxsuspension.com https://www.liquidskinzdesign.com/



1/8/2019 1:00 PM
Edited Date/Time: 1/8/2019 1:02 PM

sgrimmxdad wrote:

Good news good news, it was part #18 was loose! A little lock tite and a ordering a new gasket to be safe! Thanks so much for ...more

DaveJ wrote:

Same exact problem with a 2018 450 XCF

sgrimmxdad wrote:

Have you fixed it yet? Wondering if the same problem!

It sounds like it is exactly the same problem.

The bike would not shift beyond 2nd.

Pulled the cover off and that bolt was very loose.

Pulled off the clutch basket and the water pump drive gear. Tightened the bolt. Put the rest of it back together. Bike shifts perfectly now.

I put a chemical lock on the bolt just in case.

I'm glad you posted what you did because it helps to confirm that perhaps KTM skipped a step or didn't have their tool calibrated.

I'm glad I found your post. Sounds like KTM had some issues here.

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1/8/2019 10:51 PM

DaveJ wrote:

Same exact problem with a 2018 450 XCF

sgrimmxdad wrote:

Have you fixed it yet? Wondering if the same problem!

DaveJ wrote:

It sounds like it is exactly the same problem.

The bike would not shift beyond 2nd.

Pulled the cover off and that bolt was ...more

I also had this happen earlier this year on my 17 450sxf. That #18 bolt cocks the shift star when loose and binds everything up.

Unfortunately for me I couldn’t find an answer online at the time so I pulled the motor and tore it all apart thinking it was an idler gear on the transmission, only to find it was just that little bolt for the shift star.
I’ve been able to help a couple people since, so it’s nice to come across these threads and chime in to save people a headache.

Photo


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1/8/2019 11:39 PM

Seen that happen to a 2018 Husky 450.

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1/9/2019 1:08 AM

daboza27 wrote:

I also had this happen earlier this year on my 17 450sxf. That #18 bolt cocks the shift star when loose and binds everything ...more

I was very close to doing the same. I am thankful that I was pointed in the direction of checking this first. This needs to be added to the KTM known issues. Keep you relays and fuel filters closelaughing

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2020 YZ450F
2018 KTM 450SXF FE
2016 YZ250F 2008 CRF450R
2015 YZ250F 2008 CRF250R
2001 CR250R
2010 YZ250 2012 CRF150R
2009 YZ125 2010 KX109.5
SSR Motorsports Dealer YCF Motorcycles
TAGMX Suspension & Graphics! www.tagmxsuspension.com https://www.liquidskinzdesign.com/



1/9/2019 9:37 AM

sgrimmxdad wrote:

Have you fixed it yet? Wondering if the same problem!

DaveJ wrote:

It sounds like it is exactly the same problem.

The bike would not shift beyond 2nd.

Pulled the cover off and that bolt was ...more

daboza27 wrote:

I also had this happen earlier this year on my 17 450sxf. That #18 bolt cocks the shift star when loose and binds everything ...more

I was thinking same thing....shift drum or gear fork.

I just got lucky by pulling the right clutch case hoping that I could sneak a peak into the tranny as to pre-order parts...and there was the loose bolt. I was able to spin it with my fingers. Sneaked a wrench in and tightened it then everything worked perfectly...then tore it down and fix it right.

Thanks for sharing!!

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1/9/2019 10:56 AM

Photo
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10/17/2020 8:31 AM

Just had the same issue on 2017 450sxf FE. Out mid ride and wouldnt shift 3rd to 4th then stopped going from 2nd to 3rd.
Dropped the oil and coolant, pulled the inner clutch cover off and all looked good. Came across this thread and looked up the bolt highlighted here.
Shifting by hand 1/N/2 was fine but when going for 3rd you could see the drum moving up.
Managed to tighten enough to test again and all gears select fine.
Now taking the clutch/basket off to access it properly and threadlocknit back in.
Cheers guys saved me from getting turned over by the garage.

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10/17/2020 2:31 PM
Edited Date/Time: 10/19/2020 6:55 PM

i have a 20.5 FE and i am having down shifting issues, sometimes from 4th to third but almost always from 3rd to second when coming into a corner... almost have to stomp on the shifter to get it to go in to second. Is that a symptom of this issue?

edit: who down votes an honest question?

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Don’t piss off the old people - the older they get the less “life in prison” is a deterrent for them!

2020.5 KTM 450 SXF FE
2006 KX250

10/19/2020 11:53 AM

bvm111 wrote:

i have a 20.5 FE and i am having down shifting issues, sometimes from 4th to third but almost always from 3rd to second when ...more

Yes. Not saying it's your problem, but start with the easy stuff first. Only takes a few minutes to pop the cover off and look. Just lay the bike on it's side.

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10/19/2020 6:57 PM

bvm111 wrote:

i have a 20.5 FE and i am having down shifting issues, sometimes from 4th to third but almost always from 3rd to second when ...more

DaveJ wrote:

Yes. Not saying it's your problem, but start with the easy stuff first. Only takes a few minutes to pop the cover off and ...more

thanks dave ... i’m almost to 15 hours on the meter and plan on going through everything when i get the chance, I will pull the cover and check it out!

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Don’t piss off the old people - the older they get the less “life in prison” is a deterrent for them!

2020.5 KTM 450 SXF FE
2006 KX250

4/13/2021 11:46 AM

bvm111 wrote:

i have a 20.5 FE and i am having down shifting issues, sometimes from 4th to third but almost always from 3rd to second when ...more

DaveJ wrote:

Yes. Not saying it's your problem, but start with the easy stuff first. Only takes a few minutes to pop the cover off and ...more

bvm111 wrote:

thanks dave ... i’m almost to 15 hours on the meter and plan on going through everything when i get the chance, I will pull ...more

Hey bvm111 did you find the problem?
My 2021 450 also have the exact same problem as yours
😕

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4/13/2021 12:15 PM

Hello Gents, i posted in a different thread about having a similar problem having a hard time shifting up from 2nd to third while on the gas. i never use fourth so idk if i would have the same issue there. i have to let up or off to get it to shift. i have a 19 250sxf. is this the same problem? i read here some guy stretched the spring out and another used a file to file something.

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