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Old 06-25-2006, 07:08 AM   #1
kamanya OP
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Pissed Lost 6th.

I had to go do a conference 2 hours or so away for the last 3 days, I chose to ride there.

Not far from the house I lost 6th gear. No warning, no strange noises. Although I was wearing earplugs, I always keep an ear on the engine.

It will change up to 6th straight from 2nd or 3rd but as soon as you use engine braking it will jump to 5th and stays stuck in 5th. Then it needs some work to get it down a gear which turns out to be the real 5th . It will then not go back into 6th no matter what you do. So if you want to get it to 6th again you have to go down the gearbox to 2nd or so and then gently back up again. But no engine braking just gentle roll offs using the brakes to slow the engine so that a bit of torque is held on the gear.

What really scared me was that going down a notoriously bad pass the back stepped out big time in the wet when it suddenly changed from 6th to 5th.

I am pissed off as I have had more than my fair share of shit with this bike. I have had the gear selector forks changed under warrantee, which required a complete splittingof the casing to get there.

It goes in to the dealer on Monday.

Anyone eles even heard of this happening to these bikes?
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kamanya screwed with this post 06-25-2006 at 07:19 AM
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Old 06-25-2006, 10:00 AM   #2
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If sounds like the dealer goofed the repair the first time around. Good luck with them on the second.
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Old 06-25-2006, 11:39 AM   #3
kamanya OP
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k7If sounds like the dealer goofed the repair the first time around. Good luck with them on the second.


I am not so sure, I have a feeling that there is something that was wrong from the beginning of the bikes life that is causing this.

Gearbox problems on these things are rare, and I have never even read of a problem similar to mine. I have just gotten unlucky. It is a factory issue I am sure.
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Old 06-25-2006, 11:54 AM   #4
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Quote:
Originally Posted by kamanya
k7If sounds like the dealer goofed the repair the first time around. Good luck with them on the second.


I am not so sure, I have a feeleing that there is something that was wrong from the beginning of the bikes life that is causing this.

Gearbox problems on these things are rare, and I have never even read of a problem similar to mine. I have just gotten unlucky. It is a factory issue I am sure.
Could be but the dealer should have fixed it the first time around even with factory issues. I agree - appears to be very rare though. What are the lemon-laws like there? Is there a chance for a new start for you?
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Old 06-25-2006, 02:47 PM   #5
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How can you have a damaged shift fork and not damaged gears? Seems maybe the dealer overlooked a worn gear the first time he/she was in there.
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Old 06-25-2006, 04:17 PM   #6
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The shift forks were fine it was the rollers on them that were damaged. The bike has three; one was fine, the other had a roller missing and the last one's roller was oval.

They couldn't work out conclusively how this had happened. The bike used to get false neutrals between 3rd and 4th and between 5th and 6th. The 5th and 6th one was the worst as it would rev in neutral but collect 6th before I could catch it with the clutch. The strain I think of whacking 6th destroyed the rollers, that's my theory anyway.

The gears, drum and the rest of the stuff in the gear box was measured and photographed and deemed to be in perfect order.

I checked the stuff myself and it did not even look worn, (and I am a mechanical engineer).

So, now I am hoping that they will be mystified enough to send the engine back to KTM and give me a new one.

I don't see myself being too miffed if they have run out of 950's and send a 990 engine by mistake.
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Old 06-25-2006, 04:36 PM   #7
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Quote:
Originally Posted by kamanya

The gears, drum and the rest of the stuff in the gear box was measured and photographed and deemed to be in perfect order.

I checked the stuff myself and it did not even look worn, (and I am a mechanical engineer).
I was going to suggest try'n to get all this stuff replaced, but it sounds like you are on top of it.

Quote:
k7If sounds like the dealer goofed the repair the first time around. Good luck with them on the second.
Seems like a high posability to me also.
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Old 06-26-2006, 04:06 AM   #8
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Sorry to hear this. As you know, I had a similar problem recently. However, opposed to serious advice, I just kept going. Drained the oil, cleaned my steel filing filled sump plug and all that stuff (a freken huge amount - compared it to yours, and dare I say, I had more?) and guess what? She just keeps going and I can shift mostly with perfect results.

I have found a sometimes neutral between 5 and 6, but its not an often found thing so I am thikning that perhaps you did have either

a) A lemon to begin with how bout a full warranty and a collection of a SEnduro (go see them at KTMWC)

b) The mechanics screwed up. There is a chap (cecil penny racing in montague gardens) who has done this before, and I know he has done it successfully)
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Old 06-27-2006, 12:40 AM   #9
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Kamanya, you could check your oil drain plug, if anythings missing it could be stuck to the magnet, this might let you know if it's spmething serious or not.
I think somewhere down the line they changed the shift drum, i'm pretty sure they have a new part number. I've seen the old and new side by side and the new one has less material machined off of it.

Good Luck mate
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Old 07-11-2006, 11:26 AM   #10
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Hmmm, 'spose this would cause a bit of a problem...



Well now we know.

If you bike misses 6th as stated above then this could be the reason why.

Despite this, I really do think this is highly unusual, there are big dealers out there who have never even seen the inside of a gearbox. I know, I personally asked a few around the world.

My dealer looks after about 60 of them and this is only the third time they have gone into the gearbox and two of those where mine.

KTM are replacing everything in the gearbox.

I see normal service returning shortly. Yehaa!
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Old 07-11-2006, 12:38 PM   #11
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What was the cause?
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Old 07-11-2006, 01:04 PM   #12
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The initial failure can be speculated upon but nothing solid.

I would think something else would be broken/bent if the user caused this and.... what the hell would a rider have to do to break that, there?

I'm guessing it was faulty from day one and just decided to fall apart.

IMO, of course.

Glad you found it

I can pound mine and it just laughs at me cuz I'm a pussy......
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Old 07-11-2006, 01:31 PM   #13
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KAMANYA....my mate has the same problem right now and i actually rode his bike last night and it rode like a bag o' shite.(yep it's black).

I shall forward this link to him and hope he feels better.I must say though that his is due to be sorted by our local dealer.
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Old 07-11-2006, 08:11 PM   #14
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Thats just how mine looked. So, did they miss it the first time, and reopened it ?

Mine was due to a real hard miss shift, and the bike pop'n into gear while the RPM's were up. The dealer fixed and covered everything.
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Old 07-11-2006, 08:44 PM   #15
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Friend of mine has his in the shop right now for the exact same thing.
They cited material problems even with the replacement parts.
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