JR 50 1st gear activation
- Thread starter RICOC
- Start date
so if i dremel out the slot in the shifter mechanism i will end up with a two speed transmission????
and what would the shift pattern be? seems to me it will be down for first, middle for neutral, up for second. is that right? my sons tranny is still apart on my bench waiting for the gasket set to arrive, and since i have a trashed spare parts tranny, i just may have to try this trick before i put it together.
and what would the shift pattern be? seems to me it will be down for first, middle for neutral, up for second. is that right? my sons tranny is still apart on my bench waiting for the gasket set to arrive, and since i have a trashed spare parts tranny, i just may have to try this trick before i put it together.
Thanks Vic - I did the mod last night and it works great. The first gear is awesome - before it would hardly pull me - now I can do wheelies. My boy hasn't riden it yet but he will be very happy ( just hope he doesn't learn to get the front wheel up when mom is watching ! ).
I would offer some guidance to others doing the mod :
1) Remove the foot peg/sidestand assembly as this blocks access to the shift mechanism. It's easy to do and makes the job easier.
2) Undo the nut and pull the rear brake lever off its post as well - just more room to work.
3) Mark the kickstart lever/shaft relationship to make sure the kickstart is correctly loaded on reassembly.
4) Remove kickstart lever and oil feed pipe banjo bolt. Drain oil.
5) Remove clutch cover.
6) Remove engine casing. Note order for clutch parts.
7) Remove spring and clip plate from selector.
8) Grind away the material. I put paper towels all round the area and behind the selector to catch the grindings. Put the spring and clip plate back on temporarily to check that the selector goes into the new gear, and sits in the notch in the clip plate. ( By using the normal gear lever )
9) Clean up well, I rinsed with WD40.
10) Remove kickstart stop bolt.
11) Put clutch together and engine case on ( lining up the clutch mechanism ). It may help to turn the engine over with the kick lever to get the oil pump gear to mate. Put clutch cover. Line up kickstart lever with the marks you made earlier and fit clamp bolt, push down and put in stop bolt. Bolt on the clutch cover and other bits ( don't forget the oil pump feed line). Put in oil. Ride. I'm going to change the oil again just in case I got some filings in there.
It is very easy - it took me a couple hours, but only because I tried to do it without removing the pegs etc.
I would offer some guidance to others doing the mod :
1) Remove the foot peg/sidestand assembly as this blocks access to the shift mechanism. It's easy to do and makes the job easier.
2) Undo the nut and pull the rear brake lever off its post as well - just more room to work.
3) Mark the kickstart lever/shaft relationship to make sure the kickstart is correctly loaded on reassembly.
4) Remove kickstart lever and oil feed pipe banjo bolt. Drain oil.
5) Remove clutch cover.
6) Remove engine casing. Note order for clutch parts.
7) Remove spring and clip plate from selector.
8) Grind away the material. I put paper towels all round the area and behind the selector to catch the grindings. Put the spring and clip plate back on temporarily to check that the selector goes into the new gear, and sits in the notch in the clip plate. ( By using the normal gear lever )
9) Clean up well, I rinsed with WD40.
10) Remove kickstart stop bolt.
11) Put clutch together and engine case on ( lining up the clutch mechanism ). It may help to turn the engine over with the kick lever to get the oil pump gear to mate. Put clutch cover. Line up kickstart lever with the marks you made earlier and fit clamp bolt, push down and put in stop bolt. Bolt on the clutch cover and other bits ( don't forget the oil pump feed line). Put in oil. Ride. I'm going to change the oil again just in case I got some filings in there.
It is very easy - it took me a couple hours, but only because I tried to do it without removing the pegs etc.
I've got an 04 kdx50 that my son got last x-mas. I thought about doing this mod but ended up getting him an 03 KTM Mini Adventure instead. That bike is so much nicer for him to ride. It's faster and it has better suspension, make that WAY better suspension. The kdx50 is sitting in my storage building waiting for my 3 year old to take it over. As soon as he can ride his bike without training wheels, I will drop the front sprocket a tooth or two and put some Michelin Starcross tires on it and turn him loose on it.
