Was stuck in 4th gear. Thoughts?

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by crushing, Nov 19, 2013.

  1. crushing

    crushing Adventurer

    Joined:
    Apr 12, 2012
    Oddometer:
    42
    Location:
    SF Bay Area
    On my ride home from work today, I tried shifting from 5th gear to 6th gear. However, it just whizzed and went back to 5th probably because I wasn't in gear all the way before accelerating. Attempting to re-shift to 6th, I realized the the shifter lever was stuck.

    The clutch lever action seemed normal with proper resistant when pulling back. So, I didn't think it was the slave cylinder. After many attempts to shift/move the shifter lever, I was finally able to unstick the shift lever and change gears normally again. So thoughts on what caused this and if this indicates a mechanical problem?

    Much thanks!

    I did a quick Google search with no results.

    Current bike stats:
    '04 KTM 950 Adventure
    just shy of 40,0000 miles
    Sigutech clutch slave w/20,0000+ miles
    10w50 Motorex engine oil

    *title should read 5th not 4th
    #1
  2. bajamcguide

    bajamcguide Adventurer

    Joined:
    Jul 11, 2007
    Oddometer:
    97
    Location:
    So. Cal
    Time to pull the drain the coolant, remove the clutch cover and have a look at the shift star, detent arm and shift spring. could be that one of the pins on the shift star has worked loose and is not moving the shift drum properly. HTH
    #2
  3. dlrides

    dlrides 1:1.618

    Joined:
    Jul 21, 2005
    Oddometer:
    6,279
    Location:
    Cranial Perfection
    #3
  4. sstewart

    sstewart Long timer

    Joined:
    Nov 21, 2009
    Oddometer:
    1,059
    Location:
    Boaz,Alabama
    Just hope it isn't the shift drum,good luck!:freaky
    #4
  5. crushing

    crushing Adventurer

    Joined:
    Apr 12, 2012
    Oddometer:
    42
    Location:
    SF Bay Area
    bajamcguide and dlrides - Thanks so much for your fast responses and suggestions! These will be good starting places for me to begin troubleshooting.

    sstewart - Thanks for the well wishes. I'm hoping the issue won't be too costly and that I'm able to fix it will my limited moto maintenance experience!:eek1
    #5
  6. DirtyADV

    DirtyADV Long timer

    Joined:
    Jan 13, 2007
    Oddometer:
    3,158
    Location:
    SWEDEN, Skellefteå
    Can be checked by laying bike on its side and remove cover for the oil screen and the screen:

    [​IMG]

    Did that before heading for Russia last summer.

    /Johan
    #6
  7. dlrides

    dlrides 1:1.618

    Joined:
    Jul 21, 2005
    Oddometer:
    6,279
    Location:
    Cranial Perfection

    I remember the cost being $35-$40.

    Do a search in this forum for "Shift Arresting Coupler" and you find several threads.
    #7
  8. crushing

    crushing Adventurer

    Joined:
    Apr 12, 2012
    Oddometer:
    42
    Location:
    SF Bay Area
    Johan - Thanks for a good tip that doesn't require breaking into the engine! I was excited to try it this morning. To my dismay, all the pins seemed nicely recessed in the shift arresting coupler. I suppose it can still be faulty...but I'll have to dig deeper. Ugh. And I was hoping to ride in Baja next week :cry

    Here are more symptoms of my issue which may help with the diagnosis: I don't know why, but I thought the problem would resolve itself. Trying to change gears from 5th to 6th, 6th gear doesn't engage at speed. It just whizzes. And the shifter lever managed to get stuck again.
    #8
  9. crushing

    crushing Adventurer

    Joined:
    Apr 12, 2012
    Oddometer:
    42
    Location:
    SF Bay Area
    dlrides - Thanks again! I see you have first hand knowledge of this issue. Are special tools required to remove the clutch plates and baskets etc. to access the shift arresting coupler (SAC)? The service manual is vague. :ear I'm still not discounting the SAC.
    #9
  10. bajamcguide

    bajamcguide Adventurer

    Joined:
    Jul 11, 2007
    Oddometer:
    97
    Location:
    So. Cal
    To drain the coolant and remove the large clutch cover,( you will need to replace the gasket, about $16) only takes about 30 minutes. then you can lay under the bike and have a good look at the shifting mechanism that is behind the clutch basket.
    If you drain the oil from the crankcase you can put the bike on the center stand, and rotate the rear wheel and move the shift lever to help see what is going on
    I have seen on one bike, that the part of the shift lever that moves the star, had a crack near the weld and only worked in the down shift direction.
    on some older 950 there was a problem where the shift drum ( inside the cases) broke where the shift fork bearings rode in. But this caused problems( false neutrals) between5 and 6.
    good luck, and hope you make it to Baja
    #10
  11. Motomedic

    Motomedic Over-caffienated Raconteur

    Joined:
    Oct 4, 2004
    Oddometer:
    2,629
    Location:
    Spokane
    The only real special tool that you need is a way to remove the inner clutch hub nut. If you have an old clutch plate lying around, weld a handle to it and off ya go. Another way is to bolt an inner and and outer plate together (drill holes, etc). Also, Motion Pro sells a tool that looks like a oversize pair of vise grips, to grab the basket:

    [​IMG]

    But having said all that, your symptoms are remarkably similar to the ones I experienced when my shift drum lost a chunk (the episode that sstewart refers to :evil http://advrider.com/forums/showthread.php?t=840114), and your bike is early enough you might have the weak part in your bike.

    Good luck, buddy. :freaky
    #11
  12. LocuL

    LocuL Gnarly Infantry

    Joined:
    Dec 5, 2006
    Oddometer:
    1,670
    Location:
    Denmark - Jutland
    #12
  13. LocuL

    LocuL Gnarly Infantry

    Joined:
    Dec 5, 2006
    Oddometer:
    1,670
    Location:
    Denmark - Jutland
    ...and this is how it looked when i dropped the oil.
    [​IMG]

    I ran another good 4-5000km after this just without the 6th.
    #13
  14. crushing

    crushing Adventurer

    Joined:
    Apr 12, 2012
    Oddometer:
    42
    Location:
    SF Bay Area
    bajamcguide - Thanks for the brief guide and introducing something else to look for. I'll crack open the clutch cover post-work.

    Motomedic - Just perused your link! I almost vomited just thinking about having to split my case. I seriously hope it's not a shift drum.:puke1
    #14
  15. crushing

    crushing Adventurer

    Joined:
    Apr 12, 2012
    Oddometer:
    42
    Location:
    SF Bay Area
    Locul - Such sweet riding! I was trying to compare the sound your bike made and mine. I think, or rather hope, it's different. Sounded like a wrench was thrown in your engine.

    What happened? Hmmm...maybe I'll just go as far as 5th and pretend everything is okay :D
    #15
  16. DirtyADV

    DirtyADV Long timer

    Joined:
    Jan 13, 2007
    Oddometer:
    3,158
    Location:
    SWEDEN, Skellefteå
    Removal of the clutch basket nut without special tools, since its stuck in gear you are good, just secure the rear wheel with a strap, stepping on the rear break also might help.

    First time some muscle moster in Austria must have tighend that nut, had the bike laying on it side, secured rear wheel and a high gear.

    Tried several impact tools, electric and air pressure but none of them helped me out, ended up with a very long pipe on the wrench and have to lay on the floor next to the bike and hold my feet against it to stop it spinning on the floor, sounded like a gun was fired and I was sure the wrench snapped but it was the nut coming undone.

    Torqued it to spec with loctite after that and never had trouble getting it off ever since.

    /Johan
    #16
  17. Motomedic

    Motomedic Over-caffienated Raconteur

    Joined:
    Oct 4, 2004
    Oddometer:
    2,629
    Location:
    Spokane
    The big issue with the broken drum is not necessarily the broken pieces floating around in there, but the possibility of "going into two gears at once". If the gear is not positively held by the shift fork, it can float across the shaft and engage two gear pairs at once. What happens then is somewhat catastrophic depending on road speed, etc. think broken cases, locked back wheel, fun stuff like that.
    #17
  18. crushing

    crushing Adventurer

    Joined:
    Apr 12, 2012
    Oddometer:
    42
    Location:
    SF Bay Area
    Well, after shedding my bike of plastics, draining oil and coolant, and opening the clutch cover. Nothing was obviously wrong. Nothing was caught in the screens or magnetic plugs.[​IMG]

    The SAC seem fine too.

    [​IMG]

    Then I decided to do some fishing and hooked this fancy mental thing. [​IMG]

    Can anyone verify if it's from the shifting drum? Argh. I don't know if I'm up for breaking down my engine. At least not tonight :)

    Everyone - thanks again for all your help!
    #18
  19. bajamcguide

    bajamcguide Adventurer

    Joined:
    Jul 11, 2007
    Oddometer:
    97
    Location:
    So. Cal
    Sad to say, but it looks like part of the shift drum, a known weak link on the early 950. The drum has since been upgraded to be stronger in that area.
    There are a few good threads about splitting the cases to replace the drum.

    Sorry about the breakdown.
    #19
  20. LocuL

    LocuL Gnarly Infantry

    Joined:
    Dec 5, 2006
    Oddometer:
    1,670
    Location:
    Denmark - Jutland
    Sadly a perfect match.
    #20