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Hi guys just finished rebuilding my kdx250 was my first rebuild all new to me full rebore 67.4 to 68.5, brand new crankcase bearings and seals. A lot of time and money only to find once I put it all back together and took it for a run changing from first to second seems almost impossible a lot of grinding with clutch pulled in I have tightened the cable I've even put a small piece of pipe over to give me more travel still no difference the only thing I haven't replaced is clutch plates could this be causing the issue?

Did you test shift the tranny before you reinstalled the engine back into the frame?

Not likely its the clutch plates, does it grind in any other gear change combo? As Molly asked, did you check shifting prior to closing up the motor? Could be as simple as the something misaligned on the shift star/lever under the clutch, or could be more serious like a shift fork or gears installed incorrectly, missing shims, etc.

San wrote:Hi guys just finished rebuilding my kdx250 was my first rebuild all new to me full rebore 67.4 to 68.5, brand new crankcase bearings and seals. A lot of time and money only to find once I put it all back together and took it for a run changing from first to second seems almost impossible a lot of grinding with clutch pulled in I have tightened the cable I've even put a small piece of pipe over to give me more travel still no difference the only thing I haven't replaced is clutch plates could this be causing the issue?

Pull the clutch side cover and look at the shifting drum

Welcome to kdxrider.

bufftester wrote:Not likely its the clutch plates, does it grind in any other gear change combo? As Molly asked, did you check shifting prior to closing up the motor? Could be as simple as the something misaligned on the shift star/lever under the clutch, or could be more serious like a shift fork or gears installed incorrectly, missing shims, etc.

I can select all gear while bike isnt running and at a stand still only when i get momentum becomes a problem.

Sounds like a reassembly error

Ok so after taking a closer look it was a very simple fix I had a minor derp I didn't give myself enough clearance between the gear shift lever and the drive sprocket , Needles to say it changes throw smooth as silk now and goes hard but I would like to say thank you to all of you who tried to help just another fix to keep in the back of the mind now.

Congratulations on getting it figured out.

Also, congratulations on having a KDX250!