Transmission problem

mimafia
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mimafia
Edited Date/Time 5/20/2013 5:34pm
Hey guys I could use some advice. I've got a 2004 KX125 that's been sitting in my dad's garage since 2007. There were no issues last time in rode it in 07. But now the shifter won't shift. It will go from neutral to first and back to neutral, that's it. I think I'm going to split the cases myself but I don't really know what to even look for in there. Whatever went wrong happened when it was just sitting in the garage. Any ideas? Thanks I appreciate any help!
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mx5471
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mx5471 5/17/2013 2:23pm
5/17/2013 2:23pm
Was there oil in the tranny? Condensation in the case, not moving for 6 years, I would suspect some rust, in the climate up there. You may have to open it up and look. You may see something obvious. Or take it to a shop for their ideas for a few bucks, and see what they say.
mimafia
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mimafia 5/18/2013 11:40am
5/18/2013 11:40am
Thanks. Yeah maybe it is just rust. The shop quoted me $400 in labor just to split the cases. Plus whatever it costs to fix it and labor to put it back together! That thing isn't worth putting that kind of money into lol. I'll try and fix it myself.
mx5471
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mx5471 5/18/2013 5:25pm
5/18/2013 5:25pm
If you take the motor out, and bring them that, they can split the case in 20 minutes, and at least you can look inside and see what happened. Shouldn't cost more than a half hour worth of labor.
motofab36
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motofab36 5/19/2013 6:56am
5/19/2013 6:56am
Have you drained the oil? Even if you did, drain it again and see if it will shift while you have the drain plug out. Those drain plugs will actually stretch and grow a little from repeated use and on that kx the shift drum is very close to the case directly above where the drain bolt threads in. If the bolt has stretched or got put back in without the washer then it will rub on the shift drum and it wont shift right.

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project racer 5/19/2013 7:41am
5/19/2013 7:41am Edited Date/Time 5/19/2013 7:58am
Had an old Yamaha enduro that sat for years. Would not shift at all. When the oil was drained, it looked like graphite, about half the volume of what was spec'd drained out. Being the cheap ass that I am, especially when it comes to old bikes, I filled the crank cases with parts washer solvent several times, and proceeded to work the shifter back and forth.

Once it finally shifted into gear , I then took it off the stand, rocking the bike while in gear, and it caught another gear. Rinse ,repeat, rinse ,repeat.Eventually ,it would shift through the whole range. Threw some oil in it, rode it a bit. A few more parts washer fluid rinses , and it shifted pretty good after a few more oil changes.

Start with the easy steps ,like motofab suggested. If the drain plug / washer fix does not help, the next step would be to pull the complete clutch cover side case ,and have a look at the shifting mechanism. Splitting cases would be a last resort.
mimafia
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mimafia 5/20/2013 8:46am
5/20/2013 8:46am
Great advice guys. After looking closer I realized the oil was drained from it and there was no washer! I asked my dad and he said a couple years ago he replaced the oil for the heck of it lol. He must have forgot to put the washer back in. You don't know how excited I was to hopefully just back out the screw a bit and have it shift normally! But no luck. I will try flushing it with solvent and pull the clutch side case and go from there. Thanks!
Jakes Dad
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Jakes Dad 5/20/2013 5:34pm
5/20/2013 5:34pm Edited Date/Time 5/20/2013 5:37pm
Found this problem tonight with our RM 125, which are known for transmission problems. I was tearing it down to split the cases and found this, thank goodness it wasn't anything more. I don't like to loctite phillips head screws so it's my fault for sure.
Jake said it was hung in 4th gear and shifter was locked up. I just now noticed the metal in 2nd photo better go see what that is, maybe shifter rubbing screw for awhile but screw head doesn't look that beat up.



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