Shifting issues after first Hare Scramble

[Chopperpilot]

So after I tried (and mostly failed at) a hare scramble, I've noticed that the shifting is sometimes a PITA now. I change oil in it regularly. Now it will hit a false N ( or maybe the real one) going into 2nd gear, alot. If I do a very very deliberate shift it won't hit the false N. I say it's a false N because it will usually grab the 2nd gear for a second until you're wringing on the throttle, then it will pop into neutral. Another thing I've noticed is that coming down through the gears from 6th, I can't usually just snick through the gears with the clutch pulled in. I can get one or two gears down, then I'll have to release the clutch and try downshifting again after. The bike didn't use to do this. Any Ideas?

[Chuck78]

I would be inclined to maybe think that you have a bent shift shaft or worst case a rounded off second gear shift dog (the teeth on the sides of the gears that engage with each other and disengage when shifting gears as the gears slide across the shaft based on where the shift fork positions them). Since it doesn't downshift from 6th down to 1st with the clutch pulled in easily, I would more think you have a bent shift shaft problem. I've seen these bent many times. I pulled out my box of spare engine parts that came with a spare 220 engine, and discovered that both of my KDX shift shafts, the shift selector pawl shafts, were bent mildly and severely.

[Chuck78]

The shifter shaft comes out fairly easily if you pull the clutch case cover off the right side of the engine, not just the clutch access, the entire case front to rear that bolts onto the center right side crankcase half. This does require draining the coolant and oil. You could technically leave the coolant hoses connected and flex the clutch case to the side perhaps, but not a good idea.

[Chopperpilot]

OK, thanks I'll take a look at that. I'm probably going to wait until the long winter though and check several things then (compression, clean the KIPS, etc). Any good tips on preventing this getting bent? Can I assume that I can straighten it out?

[Chuck78]

Straightening may be difficult.... Perhaps look into the '94-'02 KX125 shift shaft mods to fit to the KDX, as it has full sized splines for stronger shifters and eliminating the weak spot where the shaft diameter steps down in diameter where the solunes are cut in. The case bearing for the shifter alao rides on the portion most likely to get bent, making it tough to really reasonably straighten without marring the bearing surface of the shaft. Brazing or Silicon Bronze and then lathe turning could smooth out any repair damage afterwards perhaps?