I split the bottom end and found the kips pin had been eaten by the transmission. I got a used transmission and installed it without major issue, spinning the shifter drum shifter through all the gears without any issue, without the shift shaft pawl installed.
When I put the shifter shaft in and shifted using the lever
(With the clutch case cover installed , I would sometimes hang between shifts and the output shaft would be hard to rotate. I was rotating the output shaft as I shifted, and even when it was hard to rotate, I was able to rotate it with more force and that didn't cause it to fully engage either. I would have to shift back down and try again, sometimes multiple times, before it would work. It's like the indexer gets stuck between, and can't fall into the next notch.
I looked back at the pictures I took when I disassembled and before I closed the cases with the new tranny and I notice that the orientation of that one gear that isn't circliped on the drive shaft (2nd gear) was facing bevel out in both my pictures, and in the Service manual it is bevel in.
My brother in law also has an 87 KDX that he parted out and that drive shaft 2nd gear was also bevel out. I realize that just because our 2 bikes have it bevel out doesn't make that the right answer, and shame on me for not double checking the manual before case assembly, but does it matter since that is not a dynamic gear?
Is there another reference that would supersede the Service manual?
Could that be the cause of my shifter problems? Or could it just be the fact that the engine isn't mounted in the frame, and I'm not fully engaging.
I realize that the right answer is to split the case and flip the gear, but before I do that I want to double check I'm not overlooking something else.
Thanks!
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