Question about 2001 KTM EXC 300

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01 ktm 300

My 01 ktm 300 won't shift out of 1st. Rode it for over an hour and had no problems. stopped for a minute and it wouldn't shift back. do you know what the problem mght be?

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You have a bent shift fork. The repair means taking the engine out of the frame then removing the top end, removing the flywheel and electrics, removing the clutch , shift mechanism and kick starter and a few other parts. THEN you are ready to split the gearbox to remove the crankshaft and then the bent shift fork. Next you get to put it all back together. This is a pretty big job for the home mechanic.

You will need an impact driver, flywheel puller, case splitter and torque wrench plus the normal screwdriver, pliers, etc.. Alternate to the special tools is taking it to the dealer and say "Fix it".
I normally tell people to take it to the shop just so they don't get into such an involved project.

Please rate this solution. Thanks

Posted on Apr 13, 2009


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Thank you for contacting FixYa with your inquiry. I have been going
over some of the older help requests that have been archieved and
trying to provide solutions for those that didn't get answered. Hope
this information helps.

You might have bent shifting forks or the dogs on the gears are worn. That would be a case split and Removal and Repair of bad parts.

Work on your shifting technique. When you want to shift from 1st to second apply up pressure with your toe and roll the throttle off and let it pop into gear. Don't use the clutch other than for starting or a few suituations where you need to idle while in gear. You might not be allowing the transmision to pull 2nd gear all the way in and it drops back to neutral.

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I have a 1998 ktm 65 sx I just bought it when we test rode it it ran good but we only took it to 3 rd gear then when rode it after getting it home the first time it went into 5th gear it got stuck there...

Thank you for contacting FixYa with your inquiry.
The first thing we need to do is eliminate the possibility that the shift lever is not interfering with anything limiting it's travel into the top three gear positions. It's possible that the lever is bent or has been incorrectly re-installed on the wrong spline position.
That being said, we more than likely have a problem with a bent shifting fork, a pall, or a shift rail, maybe even a broken gear.. There is also a good possibility the engine has been previously disassembled and not had parts replaced and the engine did not get re-assembled correctly. You will have to remove the engine and split the case to inspect the shafts, shifting forks, spacers, and shifting drum to correct the problem. This link will take you to the complete shop repair manual for this bike. Check the section 4 beginning on page 36-37.
You may have to make some holding parts and/or rent some pullers but it's not to bad of a project. A good KTM Shop can always fix the problem but it's expensive. This is a great little bike. I'm sorry it's having problems.
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It's an 01 ktm 400 exc. I can't shift into first gear and I'm getting a ratting sound sometimes. The bike still shifts beautifully up and down from second on, but when I try and downshift into...

Thanks for contacting FixYa with your inquiry.
Check externally for the obvious things first like a bent shift lever or lever re-installed in a position interfering with frame or something preventing engagement into 1st gear. I'm never that lucky.
More than likely you have either bent a shifting fork or lost a tooth on a gear or something on the shift mechanism internally is bent, broken, or has lost a clip. Drain your oil and check the plug magnet to see if any metal shavings, fragments, or parts appear.
You will most likely have to pull the engine and split the case and replace parts. You can take it to a shop or if your handy do it your self. Take a look at the link to the parts fiche and determine your preference.
2001/400/Engine/Transmission II (Don't know if your bike is a SX or EXC Racing)
You can also order a repair manual from this site or ask your dealer

If we can provide other information or service please advise.

Kind regards,


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You will need an impact driver, flywheel puller, case splitter, torque wrench and factory service manual, plus the normal screwdriver, pliers, etc.. Alternate to the special tools is taking it to the dealer and say "Fix it". I often tell people to take it to the shop just so they don't get into such an involved project and they now have a knowing eye and experienced hands working on the problem.
The repair cost will probably be $800 or so.

A “very helpful” rating for this answer? Thanks!

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