KDXRIDER.NET

Ok managed to get it off:







All of the above is the result I believe of this mysterious part, problem is I have no idea where it came from!

Ack thats not good! Time for a full inspection me thinks...

Describe "full inspection" like split the case??? Cuz i believe you're right

Gotta find out where the mystery piece came from. I'd start with removing everything on that side of the engine...

Is that part of the KIPS?

Just re-assembled my KIPS.....doesn't look all *that* familiar. Any hints, Inda?

Bottom of the shaft that goes into the actuator?

I would second what inda said. I had mine break off and make it where I couldn't shift. I lucked out and it didn't cause any damage.

The part we are talking about is 13236

No such luck, the kips, the water pump, the kick start, I even checked the casings, all looks fine
I can't match that round part to anything.

I suspect a certain ktm rider ( you know who I'm talking about, the guy who we ride with that is always looking for ways to leave us in his dust) dropped that part in your gear box while you were relieving yourself at the trailside. But seriously I do feel bad for your misfortune and hope you get it figured out and corrected soon.

Now that is going to cost ya. Seeing how the last thing you dinked with was the KIPS, it's logical that it's off of that somewhere. You need to disassemble anyway so pay careful attention and see if you might not need to split the cases if you can find what broke and can recover ALL the parts.

As we go deeper into the mystery.....




1. The currently visible shift drum operating plate has six protruding knobs about that shape... are they all OK? Probably so, eh?

2. That shift drum operating plate has a bolt that holds it to the internal shift drum itself. That bolt is located at the center of the shift drum operating plate just below the crankshaft. You should be able to unbolt and remove that plate. There is a dowel/pin that locks that operating plate together with the shift drum.
See if that pin is intact. The pin in your picture doesn't look like that pin, but it could be.



Let us know how you progress....good luck l

I stared at the manual for awhile and found this hole that's not in the manual. I found other differences between my manual and my bike, so maybe this hole is supposed to be there. Anybody can confirm?



The only thing that looks remotely similar to the mysterious part would be a piece of shift rod

Soooo, everything checks out on the outside (set aside the broken bits). Obviously the problem goes deeper cuz when I try to shift (with a socket on the shaft) it gets stuck in between gears, if I rotate the shaft back and forth, it shifts and stays on. So maybe there's more broken pieces inside the case bummer

I've gone as far as I can on my own, now trip to the mecanic to split the case Any idea how much $$$$$ I'm in for?

scheckaet Your last picture helped me a lot, Thanks, the spring shown is broken on my 220, so it wont stay in gear. Wish I could help you with yours.

Could it be this part?
http://kdxrider.net/forums/modules.php? ... _photo.php

That's a pretty good guess!

Afraid not, I already checked

That is the part I was thinking!!! Since that part is threaded it could vibrate and come unscrewed. Take a look and verify that part is there or missing. Take a picture of the entire right hand engine side so that we can all have a look for that part.

I found this lower engine shipped for $530
http://cgi.ebay.com/ebaymotors/ws/eBayI ... :IT&ih=005
Is this a decent price for an 03 model?