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kdx200 E series engine. msr shifter, avs adjustable clutch lever with terminator cable. fresh honda tranny oil. ebc clutch and springs, good basket.

only happened twice to me but maybe a sign of things to come. I had no 4th- 6th gear. shifter feels tight like it should. there is in and out movement of the shifter shaft, 3/16" at most. Normal? most of the day was spent in 1-3, and there were plenty of occasions where I did use 4th-6th.

shift drum?

anybody with experience here before I rip it down? search yielded nothing. old bike but drum looked great when in installed

I took my tranny apart a few times. You should be able to notice what is worn down too much.

Don't split the cases to inspect the gears without trying the simple things first like the spring tensioner of the drum shifter and the bolt that holds the selector to the drum first. Hope this helps

I tore the sides down and everything looks great. damn I hate to pull the cases apart for something like this....

Bent shift fork?
Since you are splitting the cases, consider replacing the main bearings and other parts that don't get the love that they should!

yea, I think thats gonna happen. dammit, now I have to finish the kdx engine and get that running before I rip this hybrid down. oh well.

newbbewb wrote:yea, I think thats gonna happen. dammit, now I have to finish the kdx engine and get that running before I rip this hybrid down. oh well.

LOL, it took me 7 months to do my E-series....because I had another bike to ride...

I'm having a similar issue on my 2001. Fell on some rocks and bent my shifter a bit and no 4-6th now. Bent the shifter back best I could and changed oil real quick. Same thing. Pulled clutch cover and basket out hoping to find something broken but nothing obvious. Any ideas???

I know this thread is a little old, but caught my eye since I had the same thing happen on my KTM 300. Postigo is onto it- "the bolt that holds the selector to the drum first." I lost 3-5 on my KTM 20 miles into a 55 mile enduro! Finished using 1st and 2nd only. Really sucked trying to make up time! Anyway, I took it apart and it was a single bolt that holds the shifting detent in place. Silly that KTM uses that one little bolt to hold the detent and selector star. It damaged the star pretty bad so had to get a new one, put Loc-Tite on that darn bolt and buttoned it back up and I've been good for a few years now. This didn't require splitting the case.
Not even sure the KDX has the same setup, but look at the shifting star/selector and whatever bolt holds it. Good luck!