this is not good, I think my gearbox is dead...

Got questions? We got answers....
User avatar
scheckaet
KDXRider.net
KDXRider.net
Posts: 3740
Joined: 12:09 am Nov 10 2005
Country:
Location: edmond oklahoma

Post by scheckaet »

Ok managed to get it off:

Image

Image

Image

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

Image
User avatar
m0rie
Supporting Member I
Supporting Member I
Posts: 2220
Joined: 10:25 pm Nov 29 2004
Country:
Location: Crescent City, CA

Post by m0rie »

Ack thats not good! Time for a full inspection me thinks...
1989 KDX 200
2007 TTR-50E
User avatar
scheckaet
KDXRider.net
KDXRider.net
Posts: 3740
Joined: 12:09 am Nov 10 2005
Country:
Location: edmond oklahoma

Post by scheckaet »

Describe "full inspection" like split the case??? :? Cuz i believe you're right :cry:
User avatar
m0rie
Supporting Member I
Supporting Member I
Posts: 2220
Joined: 10:25 pm Nov 29 2004
Country:
Location: Crescent City, CA

Post by m0rie »

Gotta find out where the mystery piece came from. I'd start with removing everything on that side of the engine...
1989 KDX 200
2007 TTR-50E
User avatar
Indawoods
Creator and Founder
Creator and Founder
Posts: 9951
Joined: 09:59 am Jun 12 2003
Country:
Location: Midwest

Post by Indawoods »

Is that part of the KIPS?
*** Administrator //***
****'95 KDX 200/****

"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
GS
Member
Posts: 644
Joined: 11:33 pm Feb 17 2005
Country:
Location: Vancouver area, Canada

Post by GS »

Just re-assembled my KIPS.....doesn't look all *that* familiar. Any hints, Inda?
User avatar
Indawoods
Creator and Founder
Creator and Founder
Posts: 9951
Joined: 09:59 am Jun 12 2003
Country:
Location: Midwest

Post by Indawoods »

Bottom of the shaft that goes into the actuator?
*** Administrator //***
****'95 KDX 200/****

"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
User avatar
motorider200
Member
Posts: 179
Joined: 04:59 pm Nov 13 2004
Country:
Location: Stillwater, Oklahoma

Post by motorider200 »

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.
97 KDX200(225)- mine
01 KDX220- brothers
97 XR400- dads
User avatar
motorider200
Member
Posts: 179
Joined: 04:59 pm Nov 13 2004
Country:
Location: Stillwater, Oklahoma

Post by motorider200 »

The part we are talking about is 13236


Image
97 KDX200(225)- mine
01 KDX220- brothers
97 XR400- dads
User avatar
scheckaet
KDXRider.net
KDXRider.net
Posts: 3740
Joined: 12:09 am Nov 10 2005
Country:
Location: edmond oklahoma

Post by scheckaet »

No such luck, the kips, the water pump, the kick start, I even checked the casings, all looks fine :sad:
I can't match that round part to anything. :evil:
rusty_chain
Member
Posts: 3
Joined: 05:13 pm Jun 07 2007
Country:

Post by rusty_chain »

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. :shock: But seriously I do feel bad for your misfortune and hope you get it figured out and corrected soon.
User avatar
skipro3
Gold Member
Gold Member
Posts: 4329
Joined: 11:58 pm Nov 04 2004
Country:
Location: BANNED FOR LIFE!!
Contact:

Post by skipro3 »

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.
Jerry

I'd rather be a smartass like carvr, than a dumbass like.... well, you fill in the blank!
User avatar
kawagumby
Gold Member
Gold Member
Posts: 927
Joined: 10:09 am Nov 30 2006
Country:
Location: California

Post by kawagumby »

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
1994 KDX200, Beta 200rr, yz125, yz250, kx100 modded for adult, gasgas contact 250.
User avatar
scheckaet
KDXRider.net
KDXRider.net
Posts: 3740
Joined: 12:09 am Nov 10 2005
Country:
Location: edmond oklahoma

Post by scheckaet »

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?

Image

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 :cry: bummer

I've gone as far as I can on my own, now trip to the mecanic to split the case :evil: Any idea how much $$$$$ I'm in for?
reddirtjoe
Member
Posts: 47
Joined: 01:24 pm Mar 07 2007
Country:
Location: oklahoma

Post by reddirtjoe »

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.
TD3
Member
Posts: 50
Joined: 05:12 am Jun 03 2005
Country:
Location: Maine, USA

Post by TD3 »

User avatar
Indawoods
Creator and Founder
Creator and Founder
Posts: 9951
Joined: 09:59 am Jun 12 2003
Country:
Location: Midwest

Post by Indawoods »

That's a pretty good guess!
*** Administrator //***
****'95 KDX 200/****

"People ate cows a thousand years ago for the same reason we eat them now. Cause they are easy to catch.We're not savages,we're just lazy. A cheetah could taste like chocolate heroin. But will never know. Those bastards are fast!!! "
User avatar
scheckaet
KDXRider.net
KDXRider.net
Posts: 3740
Joined: 12:09 am Nov 10 2005
Country:
Location: edmond oklahoma

Post by scheckaet »

Afraid not, I already checked :sad:
User avatar
80elkster
Supporting Member II
Supporting Member II
Posts: 135
Joined: 08:43 pm Jan 01 2006
Country:
Location: Maple Valley WA

Post by 80elkster »

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.
06 DR650 Farkled
91 WR250 2T
00 300EXC (Sold)
79 XS850 (Sold)
79 CR250 (Sold)
78 IT400 (Stolen)
75 G5 100 Kawi (Gave it away)
73 F7 175 Kawi (Sold)
70 175 Brigestone (Recycled)
05 KDX200(Son's)
93 KDX200
75 KT250 Trials
250 Quads
Just glad to be ridin!
User avatar
scheckaet
KDXRider.net
KDXRider.net
Posts: 3740
Joined: 12:09 am Nov 10 2005
Country:
Location: edmond oklahoma

Post by scheckaet »

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?
Post Reply