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Re: 2001 KX500 Kawasaki won't up shift without grinding
Posted: Mon May 27, 2013 2:44 am
by Qsixteen
Sandblaster wrote:Just remember Yodarad, it takes me longer than 5 minutes just to find my stinking glasses
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
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.
The best one out of my stock is 19.96mm. Most of the other 12 I have measure from 19.98-20.60mm
Re: 2001 KX500 Kawasaki won't up shift without grinding
Posted: Mon May 27, 2013 2:09 pm
by Sandblaster
Thanks!
Today I will go down to the shop and put a new bend on the lever.
It's raining so I might as well...
Re: 2001 KX500 Kawasaki won't up shift without grinding
Posted: Wed May 29, 2013 5:34 am
by Friar-Tuck
Sorry SB, What am I missing here... a 14t is smaller than the 15t right? you should have had more clearance no..???
I could understand not putting the shifter back on the same spline on the shiftshaft... I.E. raising the shifter closer to the chain and sprocket...
or am I all wet... Putting a bend in the shifter has been a tad more complex than just putting it in a vice last time I tried it.
A little Turbo torch goes a long way!
Tuck\o/
Re: 2001 KX500 Kawasaki won't up shift without grinding
Posted: Wed May 29, 2013 5:56 am
by Sandblaster
Friar-Tuck wrote:Sorry SB, What am I missing here... a 14t is smaller than the 15t right? you should have had more clearance no..???
I could understand not putting the shifter back on the same spline on the shiftshaft... I.E. raising the shifter closer to the chain and sprocket...
or am I all wet... Putting a bend in the shifter has been a tad more complex than just putting it in a vice last time I tried it.
A little Turbo torch goes a long way!
Tuck\o/
Hey Tuck.
I had a 14T on it and then put a 15T on it, but didn't try to ride it till a week later....
With the 15T there was less clearance.
So, as I attempted to up shift, the lever was grinding on the counter sprocket.
It ground so hard my big toe still hurts
Yes, if you want to bend a shift lever you better have a torch
I put it back together today with the shift lever 1 spline lower.
I have not bent it yet as I want to see if I can ride it comfortably the way it is.
If I don't like it I'll fire up the torch
Re: 2001 KX500 Kawasaki won't up shift without grinding
Posted: Wed May 29, 2013 8:53 pm
by Friar-Tuck
I apologize SB, I swore I read you replaced the 15 with a 14, (not the other way round
)
All these little annoyances seem never-ending, however look at how much you /(we) have learned from all the work you've done!
Thanks to the other guys sharing their insights, and your willingness to document it all, this stuff is very hard to dig-up (at least for me) anywhere.
Tuck\o/
Re: 2001 KX500 Kawasaki won't up shift without grinding
Posted: Wed May 29, 2013 9:49 pm
by Sandblaster
No problem Tuck.
The more we document the easier it should get over time.
Theoretically
