KTM Dirtbike Shift Drum Failure

The shift drum broke on my 2021 KTM 300 XC-W TPI after only 80 hours.

[painsrides]

Sorry it happened, but great diagnosis and fix 👍 and glad to have you back in action 😎

[Tizzy_p]

Hey mate I’m having issues with a 150 sx 2011 using the older style shift mech as yours it shifts beautifully when I have just the drum and star on but as soon as I fit the detent ( the arm with the bearing ) everything binds up and jumps I need to rotate both shafts in order to find gears, ( since I have replaced the full gearbox including the shift mech and am still having this issue! I’m no long finding neutrals between these half shifts/ false shifts as I was before the gearbox swap but I’m still uncertain that the issue is fixed! The issue it came to me was it would find neutral between every gear, the shift star is getting hung up as such while shifting untill both shafts are rotated in the same direction or holding one and spinning the other, I know they should spin opposite just wondering if you can shed some light, now, off the top of my head I’m not finding neutral between gears but it’s not fully shifting until both shafts ( gearbox shafts ) are spun in the same directions almost forcing/completing the shift when doing so the shift star will jump round the extra piece and fully locate the gear

[aski]

My 2012 engine has problems shifting and almost every gear is neutral, any ideas ? Yes i did just rebuild the motor so something might be in the wrong place

[keithpeterson]

The Austrian bikes use an aluminum shift drum vs steel of all the other brands.

Using aluminum for the shift drums is a horrible choice. They do this to try & save a little weight. These aluminum drums wear as the hard anodizing wears off & exposes the bare aluminum. This is the only reason I won't buy an Austrian bike. I wish an aftermarket company offered a steel drum.

[theterminater]

Just opened the clutch side and everything looks correct will have ro open the motor side noe snd inspect the gear drum. I fear this is what happened.

[robertbradley]

I think locking lever with roller is in the wrong place factory manual shows it pushed all the way over to the right 3o clock yours was at 10 o clock when you go through the gears might be worth checking next time your in

[nathan-nnismo]

🤦‍♂️🤦‍♂️. Remember when dirt bikes were robust and reliable……. lol. Good vid mate. 👍🏻

[Dillonpickle]

I fear this is waiting inside my 200exc 😢