Thanks man!! It was my first time tearing into the bottom end of an engine. Definitely a learning experience and now I have the tools and a little confidence for later on when the crank will need to be rebuilt/replaced… hopefully much later on 🤞🏻😄
Hey mate I’m having issues with a 150 sx 2011 using the older style shift mech as yours it shifts beautifully when I have just the drum and star on but as soon as I fit the detent ( the arm with the bearing ) everything binds up and jumps I need to rotate both shafts in order to find gears, ( since I have replaced the full gearbox including the shift mech and am still having this issue! I’m no long finding neutrals between these half shifts/ false shifts as I was before the gearbox swap but I’m still uncertain that the issue is fixed! The issue it came to me was it would find neutral between every gear, the shift star is getting hung up as such while shifting untill both shafts are rotated in the same direction or holding one and spinning the other, I know they should spin opposite just wondering if you can shed some light, now, off the top of my head I’m not finding neutral between gears but it’s not fully shifting until both shafts ( gearbox shafts ) are spun in the same directions almost forcing/completing the shift when doing so the shift star will jump round the extra piece and fully locate the gear
@@Tizzy_p this is the only gearbox rebuild I’ve done so far, so I’m not exactly sure what could be causing your issue. What you can’t see in my video is that I have a vice grip clamped on the shaft on the other side of the gearbox, so it doesn’t turn. I “think” it’s normal to have one of the shafts locked from moving while you turn the other, at least in my case it was ok like that. You might try asking on a KTM forum too. Sometimes mechanics hang out in those forums and can point you in the right direction. Good luck and thanks for watching! 😊
The Austrian bikes use an aluminum shift drum vs steel of all the other brands. Using aluminum for the shift drums is a horrible choice. They do this to try & save a little weight. These aluminum drums wear as the hard anodizing wears off & exposes the bare aluminum. This is the only reason I won't buy an Austrian bike. I wish an aftermarket company offered a steel drum.
I don’t blame you. When I changed out the faulty shift drum, the first thing I noticed was how light and cheap it felt. I wonder when they made this change? I used to have a 2008 KTM 250 EXC 2-stroke (I lived in Europe back then) and that bike was practically indestructible 😊 Thanks for watching!
@Eric Grieco Yeah, my buddy had a 2014 ktm 250sx & it developed shifting problems the same summer it was new. The shift drum was worn. It was a bummer because otherwise it was a really sweet bike. The fork performance wash also atrocious but once revalved, it was a great bike. We put a new drum in it & he sold it. He won't buy one again. I really, really want a 350 4stroke, but again, the drum has me completely turned off the bike.
@lukeweseman96 Yep, it's still the same junk aluminum shift drum. It's definitely the weak link in the system. A steel drum would be a massive improvement for ling term durability.
I think locking lever with roller is in the wrong place factory manual shows it pushed all the way over to the right 3o clock yours was at 10 o clock when you go through the gears might be worth checking next time your in
Thanks for the comment. Not sure if we have the same factory manual, but in mine, diagram 18.6.16 shows the locking lever in the 10/11 o’clock position… in diagram 18.6.18 it shows it in the 3 o’clock position, but that’s with the shift star removed. For what it’s worth.. I have two rides on the bike after the rebuild and it’s shifting great 😊
Sorry it happened, but great diagnosis and fix 👍 and glad to have you back in action 😎
Thanks man!! It was my first time tearing into the bottom end of an engine. Definitely a learning experience and now I have the tools and a little confidence for later on when the crank will need to be rebuilt/replaced… hopefully much later on 🤞🏻😄
Hey mate I’m having issues with a 150 sx 2011 using the older style shift mech as yours it shifts beautifully when I have just the drum and star on but as soon as I fit the detent ( the arm with the bearing ) everything binds up and jumps I need to rotate both shafts in order to find gears, ( since I have replaced the full gearbox including the shift mech and am still having this issue! I’m no long finding neutrals between these half shifts/ false shifts as I was before the gearbox swap but I’m still uncertain that the issue is fixed! The issue it came to me was it would find neutral between every gear, the shift star is getting hung up as such while shifting untill both shafts are rotated in the same direction or holding one and spinning the other, I know they should spin opposite just wondering if you can shed some light, now, off the top of my head I’m not finding neutral between gears but it’s not fully shifting until both shafts ( gearbox shafts ) are spun in the same directions almost forcing/completing the shift when doing so the shift star will jump round the extra piece and fully locate the gear
@@Tizzy_p this is the only gearbox rebuild I’ve done so far, so I’m not exactly sure what could be causing your issue. What you can’t see in my video is that I have a vice grip clamped on the shaft on the other side of the gearbox, so it doesn’t turn. I “think” it’s normal to have one of the shafts locked from moving while you turn the other, at least in my case it was ok like that. You might try asking on a KTM forum too. Sometimes mechanics hang out in those forums and can point you in the right direction. Good luck and thanks for watching! 😊
Exquisitely done! Nice job…
@@freddurfman9648 thank you!! 😊
The Austrian bikes use an aluminum shift drum vs steel of all the other brands.
Using aluminum for the shift drums is a horrible choice. They do this to try & save a little weight. These aluminum drums wear as the hard anodizing wears off & exposes the bare aluminum. This is the only reason I won't buy an Austrian bike. I wish an aftermarket company offered a steel drum.
I don’t blame you. When I changed out the faulty shift drum, the first thing I noticed was how light and cheap it felt. I wonder when they made this change? I used to have a 2008 KTM 250 EXC 2-stroke (I lived in Europe back then) and that bike was practically indestructible 😊
Thanks for watching!
@Eric Grieco
Yeah, my buddy had a 2014 ktm 250sx & it developed shifting problems the same summer it was new. The shift drum was worn. It was a bummer because otherwise it was a really sweet bike. The fork performance wash also atrocious but once revalved, it was a great bike.
We put a new drum in it & he sold it. He won't buy one again. I really, really want a 350 4stroke, but again, the drum has me completely turned off the bike.
Pretty sure later models switched to a bullet shift drum, my 2020 tc 125 has a billet aluminum shift drum in it, I think it’s oem so…
@lukeweseman96
Yep, it's still the same junk aluminum shift drum. It's definitely the weak link in the system. A steel drum would be a massive improvement for ling term durability.
I think locking lever with roller is in the wrong place factory manual shows it pushed all the way over to the right 3o clock yours was at 10 o clock when you go through the gears might be worth checking next time your in
Thanks for the comment. Not sure if we have the same factory manual, but in mine, diagram 18.6.16 shows the locking lever in the 10/11 o’clock position… in diagram 18.6.18 it shows it in the 3 o’clock position, but that’s with the shift star removed. For what it’s worth.. I have two rides on the bike after the rebuild and it’s shifting great 😊
@@EricGrieco glad it’s all ok Eric 👍
@@robertbradley1133 thanks for watching with such detail 😊
🤦♂️🤦♂️. Remember when dirt bikes were robust and reliable……. lol. Good vid mate. 👍🏻
@@nathan-n14nismo12 thanks man! 😊
This is very kool 👌thanks for sharing
Glad you enjoyed it! Thanks for watching 🙂
I fear this is waiting inside my 200exc 😢
Oh man I sure hope not! 🤞🏻
Than motor is clean!