74.5 250 KTM jumps out of 3rd gear -- advice needed

[Gippslander]

Hi, my 74.5 250 KTM goes well BUT when in 3rd gear and landing after a jump it goes to a neutral gear, to get out of the neutral it is occassionally ok to go up on the lever to get 3rd again, but it takes a few jabs, if you go down to 2nd it is straight into 2nd and from there you are all go again. No metal in the gearbok oil, no noises and works well otherwise. And has been getting slightly worse last few race meetings
Is this a problem anyone else has had?
I know I will probably have to tear it apart to see but advice from someone who has had the same problem or knows these bikes would start me off in the right direction.
Thanks
BTW -- got a 3rd last at Yanakie yesterday -- great track -- and the two boys I beat are really pissed!!!

[Slakewell]

Check the detente spring is ok to start with. If it's fine sounds like rounded dogs to me which will need the gear replaced , lucky all the gear box parts are the same for years and you may even find NOS.

[Gippslander]

Thanks Slakewell -- is the detent on accessable from the outside -- like on a Husky -- or do I have to "go in"?

[Slakewell]

It's normally near the sump but I don't know exactly myself. You may find a replacement spring at a good bearing shop. 

[ozktm]

To see the detent lever you can get access via the clutch cover. You will see it through a small window.
But to change or check properly is open heart surgery and full transmission removal as it is the first thing you place in before fitting the transmission.
Best to remove and check dogs on gears at the same time as this may be your problem, as slakewell said.
Also, there is a false neutral in between second and third.
See, here for similar problem from Penton forum :
http://www.pentonusa.org/forum/topic.asp?TOPIC_ID=11005&SearchTerms=neutral,gearbox

[Gippslander]

Thanks OZKTM -- the thread on the Penton Owners group tells of the same problem I am having -- but gives a few causes -- all of which seem to require a splitting of the cases -- so best to get that done before I do some real damage.
So, because at the moment I'm all out of time to be doing repairs -- is there a workshop in Melbourne that knows these motors/transmissions really well?

[ozktm]

If you were near wollongong, i'd help you get it done!
I have a workshop manual if required to help you out.
About to put one together myself in the next few weeks.
Remember, you will need top end base gaskets (if they have been glued down), plus centre case gasket.
Was the motor built recently?

Working on a 74.5 chassis at the moment.

[Gippslander]

Ozktm, Wolly is a bit far for me (from Sale Gippsland) but it sure would be good to look n' learn by watching you put one together, I have a manual (sent to me by someone here a few months ago -- have used it a lot but not very detailed on the tranny though -- after reading the link you sent me to the USA Penton Users group I think an easy way would be to buy the tranny internals from a 77-78 model -- and there are a few for sale on Ebay USA at the moment -- about $250 for the lot posted to Oz -- I don't really know much about value of 2nd had stuff -- but seems ok to me.
Yep I will get the gaskets.
The engine does not look like it has been apart anytime recently.
Purchased from the US early this year $2250USD -- a good clean bike -- there are photo's of it on here as it was listed when I "fell in love" and purchased -- from Tom Brosius -- he seems to be a name in Penton USA groups and the bike was close enough as described.
Also -- at the moment I've got front fork issues -- leaking seal on the LHS -- but also the top "releif plug" on the 35mm Ceriani's are new to me -- with a little ball and spring -- anyways on the weekend the huge Jumps  caused the oil in the "good" RH leg (read not leaking) squited out over the tank and my crutch -- sort'of funny -- lucky the pit chick stayed at home  
Are the caps with the ball and spring necessary or can I block up the hole and make em' like normal forks?

[Slakewell]

LOL yeah the forks idea was one of those great ideas on paper that didn't really work. You can just plug them it only is suppose to blead the air out.

[ozktm]

Yes i know of Tom from the forums, and saw that bike. Met Paul Danik / Doug Wilford and John & Jack penton while in the US earlier this year.
I have a 74 250 motor running in my 400 chassis atm. It has the internals from a 77. Also using the Aluminium Clutch inner hub (early ones were steel).
Beautiful gearbox, great engine all round.
I think you can purchase a video of the engine rebuild from the penton guys in the US...
Just have the guys in the US take some pictures of the dogs on the gears before purchasing. Send out a help line on the Penton forum and they may help you out with a gearbox at a more reasonable price, plus the added security that they really want to help you.
Forks, yes, check the penton forum, the trick from the day was to block this off, as it make the fork sealed and uses the air section under compression.
Can take some pics of my other motors as they are apart to give you an understanding of how it goes together. See what i can do this week/end.

[Big John]

Peter at Bultaco parts Australia, is at Cowwarr, He worked at Bert flood for years. He may be worth try. He is a good mechanic and has helped me out more than once. 

[Gippslander]

Thanks John,

Gave Peter a call today -- yep he rembers well the KTM days from Floods and will give me some guidance -- thanks for that referral -- really takes the pressure of me knowing I have someone who knows to put me in the right direction if I get lost.