My ktm 65 changes gear up the box no problem but when i come down the gears it goes down a gear but the shift sticks down and i have to flip it back up gently to shift down another gear
can any body help me
kind regards stuart
Not sure bout that bike specificaly, probly there is a spring on the gearshift shaft , or something to return the lever and shift drum back whenever actuated. no matter what it is, you gotta split the cases to fix it .
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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.
http://www.scribd.com/doc/44875530/20355873-1998-03-KTM-60-65SX-Service-Manual 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. Thanks again for contacting FixYa. TF
You have an internal problem with the shift mechanism.You will need to remove the clutch cover to identify what is broken.It is rare that you can't fix a problem such as this from behind the clutch cover.(ie no need to split the crankcase).pull of the clutch cover & look to see if when you try to select gears if the selector drum turns. It should then be apperent what has gone wrong.(circlip fallen off,selector drum actuator or spring broken)
If you find something broken you need to find all broken pieces before it goes back together so it/they don't find there way into the gearbox or BANG your gearbox will go.
Hope this helps
Regards Andrew porrelli
Do the gears 'crash' when attempting a shift--that might signal that the clutch is not releasing fully. If it just won't go into the gears, the shift fork inside may be bent from the intensity of racing (stomping the shift lever). The engine case must be taken apart and the fork and gears examined--likely the fork will need replacement.
If it's a later model (post 98), then I have an idea what's happened. On the rounded ball end of the gear stick that goes in the box, there is meant to be a plastic bush that is only a very loose fit on the end of the stick. If it has dropped while either removing or replacing the gearstick, and fallen into the area at the back of where the gearstick actuates the shift rail, then apart from having a very sloppy gearstick, you won't be able to move the shift rail backwards - which is what happens when you move the gearstick forward (1st,3rd,5th). This should be fixable from in the cab. Of course, if you have an earlier model, none of the above applies, as you have the gearstick moving only one of a choice of three shift rails with no bush in that area. The only thing that happens to those is the spring on the gearstick breaks (that can't be replaced on its own!)