KX500 Gearbox

[FireKwaka]

I am hoping someone might have some knowledge on this topic, split my cases in attempt to fix my '83' A1 from jumping out of gear. Can't see anything obviously wrong apart from the dogs and slots a little rounded on the gears. I have noticed the '84' A2 has a different input shaft, drum assembly and gear change mechanism so I am assuming this may have been Kawasaki's way of solving the problem. Does anyone know if the A2 setup will fit into the A1 engine? Any advise on this problem would be greatly appreciated as in the effort for self preservation I need to stop the big girl from jumping out of gear if I am going to go my hardest at MX.

[Stevo17]

I am not an expert but do have a bit of experience with the 84. The cases are different on the 84 and the selector setup is different.  I don't think you could slip the 84 into the 83. I did try to put the 84 tranny into 83 cases but they were quite different around the selector drum.

[JohnnyO]

The rounded dogs are what causes it to jump out of gear, either have the gearsets back cut or replace the worn gears. I'm pretty sure the gears and shafts are inter changable, i put a '83 main shaft in my '84 500.
Holeshot Buddy will know for sure, he gave me the shaft for mine.

[holeshot buddy]

gear sets and seperate gears are interchangable 83/84/85
you might need to undercut your dogs
also if you mix up the shift forks (2 look very similar 3rd and 1st i think)
it will jump out of third gear check your manual it described each fork seperate
also i have struck wear and hairline cracks and chips in shift drum in the 3rd
gear groove

[FireKwaka]

Thanks guys, yes third gear is the main offender and one of the shift forks does have a mark on it were it shouldn't, I think your on the money Holeshot

[Ktm181]

If you need your gears under cut (either up or down) contact Coljen gears in victoria (google them), they are GOOD and charge the correct price, not the inflated rip-offs that some will try, they also use a machine when back cutting, all dogs still contact as they should. I have just had a look at some gears they did for me 10,000+ kilometres ago, still perfect.
I believe they will also repair and/or remake new gears if needed,shafts too from memory.

Talk to Colin or Jenny.

Kt

[FireKwaka]

I have a 84 transmission, selector drum and sift mechanism coming from the states as I want to try the newer model setup, I am hoping the gears and dogs are better then my existing set, if not I will get them undercut as recommended, thanks for the lead KTM181.

[Ktm181]

I have a 84 transmission, selector drum and sift mechanism coming from the states as I want to try the newer model setup, I am hoping the gears and dogs are better then my existing set, if not I will get them undercut as recommended, thanks for the lead KTM181.

no probs FireKIwaka. Coljen do good work at a very reasonable price, less than half what a thief in Sydney wanted ($1000 versus $380 for "up and down" cutting.) All the dogs meet at the same time too, which is how its supposed to, i have seen a "few" from others where they dont all meet the same which just mean faster wear and missed shifting.

cheers,
Kt

[Ted]

I have a 84 transmission, selector drum and sift mechanism coming from the states as I want to try the newer model setup, I am hoping the gears and dogs are better then my existing set, if not I will get them undercut as recommended, thanks for the lead KTM181.

no probs FireKIwaka. Coljen do good work at a very reasonable price, less than half what a thief in Sydney wanted ($1000 versus $380 for "up and down" cutting.) All the dogs meet at the same time too, which is how its supposed to, i have seen a "few" from others where they dont all meet the same which just mean faster wear and missed shifting.



cheers,
Kt

Very helpful and very good. Call them first

[holeshot buddy]

colin at coljen made gears for me on my rm500
back in 1983 so i think he knows what he is doing

[FireKwaka]

Looks like Coljen it is, my first ever attempt at an ebay purchase and I get out bit in the last 5 seconds!!!! I would still like to try the 84 selector setup if anyone knows were I could get one?