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I have had an xt500 for a while, but I can not get it to shift right. I wont bother to take you through all the agony, but the problem is basically this: It wont shift into 2nd, just rattles the shifter and grinds or nothing. Been through all the factory adjustment procedures, clutch, shift pawl, etc. and no change really. Ive been able to make it worse by throwing the settings out of whack on purpose though.
Sounds like a shift fork issue, I did split the case and found some chewed up gear dogs, Im guessing that was the one that was grinding and complaining...one of the forks had a bit of ugly on it, that was the fork attempting to push that chewed up gear, so that makes sense to me.
I replaced these items, replaced the shifter shaft, pawl mechanism, etc etc. Havent messed with it in a while.
Today I was puttering around the shop and I operated the XT's shifter by hand a bit. it wasnt really shifting, but I noticed that the countershaft sprocket moved out at one point with the shifting motion. So I grabbed the countershaft sprocket and was able to move it in and out without operating the shifter.
Ive seen some play here on bikes in the past, but this felt like more than I was used to. I ran around and felt all my other bikes, all had less play, most much less.
My thinking is that there are gears on that shaft, and when the mechanisms are trying to slide the gears, some of the motion is going to be wasted as the whole shaft moves. I could shim it on one side or the other, the trick I suppose is knowing which position it SHOULD be in, you know, like shim it up on the sprocket side, clutch side, or split the difference....
I am thinking this may be my smoking gun! What do you guys think?
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1972 S2 350, 1972 F9 350 Bighorn, 1975 KX400, 1981 YZ465, 1980 XT500 (Built for MX) , 1987 KD80, 1995 MZ Skorpion, TTR 125, 1994 KDX200 , 1978 Mobylette, 1985 KX350R-F91m (Frankenstein) and a Doodle Bug
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