09 Ktm 450exc will not shift. Right side cover is off.

bombhills415 · 10-11-2012, 08:23 PM

While fixing oil transfer on a 09 450 exc with 64 hours (oil pump cover O Ring) we had the right side case cover off and performed the surgery. Ended up breaking a bolt in the inner clutch hub, and long story short the the cover is still off the bike while a new clutch hub gets here...

The shift lever will not engage the shifter drum. There is play in the shift lever but it will not go as far as to move the drum on the right side of the engine. This should be independent of whatever situation the clutch is in, correct? Any ideas why this is happening ? Any ideas how to fix it?.. Clutch hub will be here Wednesday and hoping to not have a second time consuming problem to deal with.

Bullwinkle58 · 10-12-2012, 09:38 AM

My bro-in-law had the same problem on his YZ 250. The ratchet mechanism fell apart somehow, so we just put the ratchet mechanism back together & all is well. If you look at an exploded diagram (you can go to a site like motosportoutlet.com & look under OEM parts for the diagram), the ratchet is on the end of the shifter shaft & you access it from the clutch side. We had to remove the cover behind the clutch basket to get to it. Hopefully its as easy to get to on your bike as his was. Easy fix. Dont forget to replace the gasket for the cover behind the clutch basket (assuming yours comes apart that way. I'm not familiar with KTM's).

bombhills415 · 10-12-2012, 02:56 PM

Thanks, does anyone have any KTM specific advice?

bombhills415 · 10-14-2012, 07:54 PM

Bump..

clapped_r6 · 10-14-2012, 09:56 PM

pitchurz would help to visualize......

also ktmtalk is THE resource for this kind of stuff......

bombhills415 · 10-17-2012, 12:26 PM

Definite n00b issue, moderator please delete thread..

10-11-2012, 08:23 PM	#1
bombhills415 ^OP n00b Joined: Oct 2012 Oddometer: 4	09 Ktm 450exc will not shift. Right side cover is off. While fixing oil transfer on a 09 450 exc with 64 hours (oil pump cover O Ring) we had the right side case cover off and performed the surgery. Ended up breaking a bolt in the inner clutch hub, and long story short the the cover is still off the bike while a new clutch hub gets here... The shift lever will not engage the shifter drum. There is play in the shift lever but it will not go as far as to move the drum on the right side of the engine. This should be independent of whatever situation the clutch is in, correct? Any ideas why this is happening ? Any ideas how to fix it?.. Clutch hub will be here Wednesday and hoping to not have a second time consuming problem to deal with.

10-14-2012, 09:56 PM	#5
clapped_r6 The Spoad Warrior Joined: Jan 2006 Location: Ridgefield, WA Oddometer: 2,168	pitchurz would help to visualize...... also ktmtalk is THE resource for this kind of stuff...... __________________ none of us are as dumb as all of us

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10-12-2012, 09:38 AM	#2
Bullwinkle58 Adventurer Joined: Feb 2012 Oddometer: 26	My bro-in-law had the same problem on his YZ 250. The ratchet mechanism fell apart somehow, so we just put the ratchet mechanism back together & all is well. If you look at an exploded diagram (you can go to a site like motosportoutlet.com & look under OEM parts for the diagram), the ratchet is on the end of the shifter shaft & you access it from the clutch side. We had to remove the cover behind the clutch basket to get to it. Hopefully its as easy to get to on your bike as his was. Easy fix. Dont forget to replace the gasket for the cover behind the clutch basket (assuming yours comes apart that way. I'm not familiar with KTM's).

10-12-2012, 02:56 PM	#3
bombhills415 ^OP n00b Joined: Oct 2012 Oddometer: 4	Thanks, does anyone have any KTM specific advice?

10-14-2012, 07:54 PM	#4
bombhills415 ^OP n00b Joined: Oct 2012 Oddometer: 4	Bump..

10-17-2012, 12:26 PM	#6
bombhills415 ^OP n00b Joined: Oct 2012 Oddometer: 4	Definite n00b issue, moderator please delete thread..