Hey group new to owning a kx500 not new to riding and wrenching I got my 2000...

Hey group, new to owning a kx500, not new to riding and wrenching. I got my 2000 kx500 on a trade last year, just needed crank seals but complete. Put new seals in, gears and everything looked good and put it together. Once the engine is together, I can't find neutral. Split the cases, checked over everything again, with a Clymer manual and service manual for specs. All within specs and shift forks look good. Put back together and no neutral again??? WTF am I missing? Three times I checked everything and still no neutral. Anyone have any ideas? Thanks in advance for any help

28 comments
  • Mainly first and second

  • Gearshaft rabbit ear spring on backwards

  • is the gear lever floppy?

  • Nope

  • Huh?

  • Forks aren't in correct slot or wrong one in wrong place. Depends if your getting the rest of the gears . Should be there if the rest of the gears are there.

  • Maybe shift gear pin not aligned correctly. Shift drum not sitting flush with it or case

  • It's there somewhere

  • Is the shifter on tight

  • Shift spring to much tension could be

  • Shift forks, drum, gear selector and detent are where they need to be, I can go through all the gears, up and down. It is a little effort to get the shifter to move but it goes through the gears, just no neutral

  • Check that spring that those 2 shift blades are held together by. And that rod in the center of em. I once had the wrong tension spring in on those and it caused all kinds of frustrating shit. Also if the actual shift lever isn't on and TIGHT It can fool ya if it's just a little bit loose . MAke sure that pin that is in the center of those two blades that move the drum gear is down and tight. What else um the spacer on the inside of the little stopper on the other side of the drum gear with the spring . Make sure it's there. ANd the pin that lines the drum gear to the shift drum on the inside . Make sure on that too.

  • I'll check all that out and see what I find. Thanks and I'll be back to give an update

  • Alex Ward turns out that 5th gear is stuck to the main shaft and the circlip was the culprit.

  • Ah yes, the circlip, we replace those when the engine comes apart, thanks for the update now get it back together and get back to ripping it up!!!!

  • Yeah, I need to find a main shaft and 5th gear. Hopefully I'll get it back together soon...I want to ride this thing!

  • Is it not repairable?

  • I can't get the gear off of the shaft, I think pieces of the circlip are jammed in it.

  • Want me to give it a go?

  • Possibly, if 5th gear is supposed to spin...it doesn't. It's almost like it welded itself to the shaft

  • Input or output?

  • Input

  • It's the gear next to the one that's a part of the shaft

  • I can work it over if you like and may be able to save it, won't know till I see it. Send it all and I could replace all the clips while I have it

  • are the 2 parts of the shiftdrum assembled right?? i check shifting through whole gears, before put more together as only the crankcase-halfs

  • 5th gear is stuck on the main shaft, shift drum, forks and all that are okay. The circlip shit the bed and I didn't know it.

  • the circlips are little bastards.. ;) ...replace all! and by replacing, watch out, they have a sharp and a round edge .. install the sharp edge to the outside of the gears for maximum strength ... with the round edge to the outside it can pop out and the gear is able to move sidewards...

  • the circlips are little bastards.. ;) ...replace all! and by replacing, watch out, they have a sharp and a round edge .. install the sharp edge to the outside of the gears for maximum strength ... with the round edge to the outside it can pop out and the gear is able to move sidewards...