2001 KX500 Kawasaki won't up shift without grinding

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Sandblaster
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2001 KX500 Kawasaki won't up shift without grinding

Post by Sandblaster » Sat May 25, 2013 10:45 pm

2001 KX500 Kawasaki won't up shift without grinding.
On my SM project, after running 6 heat cycles on it I rode it for a few hundred yards up and down the street.
It shifted fine through 4th gear with no issues.
On Friday I ran it for 20 minutes trying to get some starting heat numbers.
After the test I had to take it for a quick ride.
I pulled the clutch in and clicked it into first.
I gave it some throttle and let the clutch out.
It took off just fine.
Pulled in the clutch and upshifted into second and GGGGrrrrrrrtttt, GGGGrrrrrtttt... the gears were grinding.
But the bike went into second when I let off on the gas.
I thought I blew a shift, although I didn't see how that was possible as I wasn't getting on it.
Then I tried to shift into 3rd and GGGGrrrrrrrtttt, GGGGrrrrrtttt...the gears were grinding again..
I let off on the gas and it was in 3rd.
So I rode it back to the shop and parked it :-(
Today I pulled the clutch cover, clutch basket, ect so I could get a better look at the shift mechanism.
All the springs are there and in place.
I pulled the shift shaft out and inspected the pal, springs, everything that I can see that would be a problem.
Then I compared it to another shift shaft asy I have and it looks and functions exactly the same.
I spend about 30 minutes reading the Clymer but didn't see anything out of place.
I'm stumped, any ideas?
Here is a pic with the shaft removed.
shifting issue 4.PNG
shifting issue 4.PNG (165.59 KiB) Viewed 3057 times
The shaft that came out of the bike is on the right.
shifting issue 2.PNG
shifting issue 2.PNG (1.2 MiB) Viewed 3063 times
Another view..
shifting issue 3.PNG
shifting issue 3.PNG (424.13 KiB) Viewed 3063 times
If bikes are for kids I'll never grow up.

Motorrad
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Re: 2001 KX500 Kawasaki won't up shift without grinding

Post by Motorrad » Sun May 26, 2013 3:50 pm

Currently going out to Brunch with USMC500. Hmmm... Do I have a Bromance going on?


naw. its so Our wifes can meet for the first time. at a KICK ASS BAR! that does brunch. thats our story, and we are sticking to it...




If its grinding... as if you arnt pulling in the clutch.. you shouldnt be looking at shift mechanism.
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Re: 2001 KX500 Kawasaki won't up shift without grinding

Post by Sandblaster » Sun May 26, 2013 3:57 pm

Bromance?
Hilarious!
I'll be reinspecting ever inch of the clutch today...
If bikes are for kids I'll never grow up.

Motorrad
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Re: 2001 KX500 Kawasaki won't up shift without grinding

Post by Motorrad » Sun May 26, 2013 4:00 pm

Sandblaster wrote:Bromance?
Hilarious!
I'll be reinspecting ever inch of the clutch today...

make sure the washer's shims are in the correct order?

pull the clutch arm.. inspect it

inspect the push rod.


inspect the clutchc cable. they do strange things when they bust internal. (stretch like a rubber band when you pull in the clutch)
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Re: 2001 KX500 Kawasaki won't up shift without grinding

Post by Sandblaster » Sun May 26, 2013 4:17 pm

Might go ahead and install the modded clutch arm while I have it apart...
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Motorrad
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Re: 2001 KX500 Kawasaki won't up shift without grinding

Post by Motorrad » Sun May 26, 2013 4:21 pm

Sandblaster wrote:Might go ahead and install the modded clutch arm while I have it apart...

not like its hard... you can install that with the motor together.... In the bike.. in about 3min...

but dont untill you solve your problem...

as it will change engagement and travel distances...
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Re: 2001 KX500 Kawasaki won't up shift without grinding

Post by Sandblaster » Sun May 26, 2013 9:37 pm

Just remember Yodarad, it takes me longer than 5 minutes just to find my stinking glasses :geek:

I think I may just have found the problem.
The kick idler gear has approximately 1/16" of play in it, that's rocking on the shaft :shock:
The shaft measures approx 19.94mm and the ID of the gear measures 20.02mm
I think the shift pawl was grinding on the gear although it doesn't show it.
Then again it happened only a few times and I didn't force the issue.
If this is correct that would explain why the bike went into gear even though I heard a grinding sound..
It would also explain why my clutch seemed to work just fine when starting and stopping...
I'll know when I locate another kick ider gear.
I can't seem to find the specs for the ID measurement...

More later.
If bikes are for kids I'll never grow up.

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Re: 2001 KX500 Kawasaki won't up shift without grinding

Post by Sandblaster » Sun May 26, 2013 9:51 pm

Found some other idler gears but they were worn even worse then mine :(
I have to admit that it looks like it is in great shape but without some specs I'm groping in the dark... For now :)
If bikes are for kids I'll never grow up.

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Re: 2001 KX500 Kawasaki won't up shift without grinding

Post by Sandblaster » Sun May 26, 2013 10:11 pm

Ok, found the problem....
I have to say that I feel like a real dummy...
Guess where the hang up and grinding was coming from....
SHIFT LEVER.PNG
SHIFT LEVER.PNG (1.17 MiB) Viewed 3020 times
From the first time I rode the bike to the second time I changed the front sprocket to a 15T from a 14T.
My Dad was no mechanic but he always said, if you changed something and now there is a problem, go back and look at what you changed..
I had completely forgot that I changed the sprocket :lol:
Oh well, at least I can laugh at myself and perhaps someone will learn a valuable lesson :geek:
If bikes are for kids I'll never grow up.

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Sandblaster
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Re: 2001 KX500 Kawasaki won't up shift without grinding

Post by Sandblaster » Sun May 26, 2013 10:44 pm

If bikes are for kids I'll never grow up.

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