990 - Missing 3rd-6th gears

Discussion in 'KTM 950/990' started by HellSickle, Aug 19, 2019.

  1. HellSickle

    HellSickle Scone Rider

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    During a long ride this weekend I noticed my 990 shifting starting to get a little notchy. In town today I suddenly have only 1st and 2nd gear. I suspect the problem will be obvious when I remove the right engine side cover, but I suspect others in here might have already experienced this problem. Spring or shift cam issue is my guess. Thoughts?
    #1
  2. Johnf3

    Johnf3 Long timer

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    Just in case you have not checked anything yet, the first thing is to check the shift lever itself. It gets loose and hits the case, which causes issues when you try to shift out of the lower gears.
    #2
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  3. HellSickle

    HellSickle Scone Rider

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    Thanks. I already checked that.

    I did some more research. I'm suspecting that one of the 6 pins on the shift mechanism may have backed out. I'll pop out the oil filter screen and take a peek with a scope to try and confirm. The symptoms fit. It the pin to shift from 2nd to 3rd backed out it would still allow shifting between 1 and 2, but no higher. Here's some picture from another thread.

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    #3
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  4. DirtyADV

    DirtyADV Long timer

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    You don't even need a scope it can be seen after removing the oil screen.

    /Johan
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  5. DirtyADV

    DirtyADV Long timer

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  6. HellSickle

    HellSickle Scone Rider

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    I pulled the filter screen & took a peek with my scope. One of the steel dowels on the hub has backed out as I suspected. Fortunately it hasn't fallen out and disappeared into the bowels of the beast.

    When I get the new hub I'll probably tack weld the dowels into place to eliminate this problem.
    #6
  7. DirtyADV

    DirtyADV Long timer

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    One looked like it was a tiny bit out just got a screwdriver in there and gave it a few hits in that spot. Not looked at it since, many years and kilometers ago.

    Welding sounds overkill.

    /Johan
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  8. HellSickle

    HellSickle Scone Rider

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    Overkill? Yes, I'm an anal-retentive mechanical engineer. :deal

    I will at least thoroughly peen the area around each pin. Bike is at 50k miles, so that will probably do for the next 50k.
    #8
  9. Rharr

    Rharr Been here awhile

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    center punch where the pin and hub meet should do nicely in peening it in place.
    #9
  10. Zuber

    Zuber Zoob Supporter

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    Steel pins and aluminum housing means no welding. I'd just replace it, chances are you'd get no more problems.
    #10
  11. HellSickle

    HellSickle Scone Rider

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    Didn't realize it was aluminum. I am replacing the entire assembly. It would be silly to go to all that work and not replace it. Steel in aluminum is not a good solution for something that goes thru a lot of temperature cycles. Aluminum expands at 2X the rate of steel. I guess I'll just peen the shit out of the aluminum surrounding the pins.
    #11
  12. HellSickle

    HellSickle Scone Rider

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    Got the part installed. I ended up with 7 neutrals, as the clutch was disengaged. Figured out the outer pressure plate wasn't properly aligned with the basket splines. Easy fix.

    However, now my oil pressure light is on. I didn't open up the oil pump or remove it's gear. Any thoughts before I put her down and open the entire side back up? I'm going to try and peek in the filter screen opening to see if the oil pump gear is turning with the engine.
    #12
  13. HellSickle

    HellSickle Scone Rider

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    Never mind. Problem found. I must not have aligned the clutch gear with the oil pump gear before I hit it with the impact wrench. At least all of the pieces were right there. My mechanic needs a good ass-kicking. :baldy

    upload_2019-9-27_17-5-15.png
    #13
  14. AdvRonski

    AdvRonski They call me......Ronski

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    Well, that's what you get for using an impact gun.
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  15. Zuber

    Zuber Zoob Supporter

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    Plastic gear. Everyone does it once.
    #15
  16. HellSickle

    HellSickle Scone Rider

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    No, it's steel.
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  17. Zuber

    Zuber Zoob Supporter

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    If you broke a steel one... You need to put down the hammer and air gun.
    #17
  18. HellSickle

    HellSickle Scone Rider

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    The torque needed to seat the nut is enough to break the gear, impact wrench or not.
    #18
  19. CRW

    CRW I dont want a pickle

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    I get that. But using a wrench or socket will allow you to feel the something is not seating. The impact just drives it home with out finesse or feel. Thats a lot of force to shear a hardened gear!! Have fun with the repair!
    #19