Shift drum on a 03' KX85

[hairbear65]

I'm looking for someone that knows the orientation of the shift forks and shift drum on a KX85.
The KX85 has 1 shift fork on the drive shaft (closest shaft to the crank)...

The shift drum has 2 slots....
The 1st slot near the clutch side is not continuous around the shift drum.
The 2nd slot (nearest the flywheel side) is a continuous slot all the way around the drum itself.

I need to know what slot on the shift drum this drive shaft shift fork fits into to follow....the first or second slot?

The drive shaft shifting fork is the smallest of the 3 shift forks in the KX85.

I rebuilt the lower end and haven't been able to get the bike to shift since...the FSM(factory service manual) is pretty vague on what goes where and the drawings aren't very much help either.

Any help or knowledge you have with the KX85'....I'd appreciate it...and I'm sure my son will...plus it'll stop me from committing myself.

Thanx in advance...
Tom

[chase114]

Boy I wish I could help you, I've done 2 85's, 1 250 & 1 100 this year and can't tell you which one. Once your putting it back together you should be able to tell where it goes and it should all fall into place. I wouldn't think you could get it together wrong with out some force. I guess I've just been lucky.

[hairbear65]

The 2 shift forks are easy...they go in both grooves...the drive shaft one is the one I'm questioning...it has to be the only reason this thing won't shift. ...it didn't take much force to get the fork to seat in the groove closest to the flywhel side...I just lifted it with a pick while holding the gear sets in place....when its seated in that groove...it appears that the trannys in neutral as both shaft spin freely. I'm going to break the cases again...now for what feels like the 20th time.
Learning curve on this one is WAYYY too much!! It's now not fun to be in this tranny..it's kicking my arse..

[chase114]

Good luck, we've all been there and it only gets easier. It's really the only way to learn.

[KDXGarage]

In the future, you may want to snap a few photos of whatever you are taking apart, as you are taking it apart.

[hairbear65]

I did...I snapped some pics of the clutch side...but when I pulled the cases apart the tranny just about fell out.
Thanx for replying with the idea though.

Tom

[hairbear65]

Well before pulling the motor back out of the frame..I hooked th chain up so I could spin the trans taht much easier...still NG.

I pulled the motor...spit the cases again!

I was correct in that the drive shaft shift fork has to be inserted into the drum groove closet to the flywheel side...or the one furthest away from the clutch side.

So...as of right now....I have no clue why this thing won't shift.


The shift shafts and forks are to spec...no bends...nothing.
I never had either gear set apart so they're still the way they were when I first split the cases.

I'm quitting for the night...I had enough.

[chase114]

Does it just stay in a nuetral position or act as if it is in gear and won't shift out of it?

[ironoxide1]

...i am curiously paying attention to this thread, as my kids kx85 seems to be doing the same thing...my bike is in 1st gear and wont come out...****er moves with no resistance

[hairbear65]

My problem ended up being a set of gears placed on the wrong side of one of the cir-clips....my doing...but I do not for the life of me remember removing that cir-clip and then pulling the gears off and then replacing them in the incorrect order. I must have done it though....too many concussions I guess.
Anyway..once I placed the gears and circlip correctly the bike shifted excellent.

If your sons bike is stuck in first gear, then you may have a bent shift fork...not allowing the shift drum to rotate properly...any resistance and it most likely won't shft. I'm afraid you'll have to split the cases to actually find out whats going on. Before doing so though make sure that the shifter is properly attached to it's spline and not slipping when you try to shift....keep is simple at first...

Tom

[Polar_Bus]

Originally Posted by hairbear65

My problem ended up being a set of gears placed on the wrong side of one of the cir-clips....my doing...but I do not for the life of me remember removing that cir-clip and then pulling the gears off and then replacing them in the incorrect order. I must have done it though....too many concussions I guess.
Anyway..once I placed the gears and circlip correctly the bike shifted excellent.

If your sons bike is stuck in first gear, then you may have a bent shift fork...not allowing the shift drum to rotate properly...any resistance and it most likely won't shft. I'm afraid you'll have to split the cases to actually find out whats going on. Before doing so though make sure that the shifter is properly attached to it's spline and not slipping when you try to shift....keep is simple at first...

Tom

How about investing in a service manuall ? The manuall will explain exactly how to orientate the shift fork assembly (so you won't have to tear the tranny apart a 3rd time)

Let me tell you a quick story about John Doe who did a "no manuall" engine rebuild. See part ref. # 92152 ? Thats a flanged hardened steel collar. John Doe installed that collar backwards, and that collar fell out at about 11,000 rpm's hard on the gas, jammed itself between the clutchbasket gear and the primary crank gear and BENT the crankshaft. That $2.00, incorrectly installed collar trashed a $190 crankshaft (probably much more damage as well), All because John did not have the Kawi manual as a detailed reference.

[hairbear65]

I had a FSM....I just never thought of looking at the expoded view of the driveshaft gears, why would I ....because I had no idea I took them apart....Lol....I couldn't remember doing it. A guy on the forum seen one of my pics and noticed the cir-clip being on the wrong side....we hooked up and he helped me figure it....terrific guy he was to help me out as he did.

[hairbear65]

and

The shift drum was oreintated correctly....it was two small gears on the countershaft sprocket main shaft that were causing me all the problems. FSM manuals are sometimes very vague about assembly and cover numerous models. They are not a tell all...end all. They certainly help though. Pics' are worth a thousand words as well.

Thanx for the info though