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

Discussion in 'Thumpers' started by bombhills415, Oct 11, 2012.

  1. bombhills415

    bombhills415 n00b

    Joined:
    Oct 11, 2012
    Oddometer:
    4
    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.
    #1
  2. Bullwinkle58

    Bullwinkle58 Adventurer

    Joined:
    Feb 8, 2012
    Oddometer:
    61
    Location:
    Southern California
    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).
    #2
  3. bombhills415

    bombhills415 n00b

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    Oct 11, 2012
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    Thanks, does anyone have any KTM specific advice?
    #3
  4. bombhills415

    bombhills415 n00b

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    Bump..
    #4
  5. clapped_r6

    clapped_r6 The Spoad Warrior

    Joined:
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    Oddometer:
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    Ridgefield, WA
    pitchurz would help to visualize......

    also ktmtalk is THE resource for this kind of stuff......
    #5
  6. bombhills415

    bombhills415 n00b

    Joined:
    Oct 11, 2012
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    4
    Definite n00b issue, moderator please delete thread..
    #6