93 KX500 Locked in 3rd

[Bowtie]

I have a friend with a 93 KX500. The motor, top and bottom, has been gone through. When you shift into 3rd the motor locks up. If you skip it and go from 2nd to 4th it runs fine. Any ideas before we tear into it. Anybody have this happen before

[Hillclimb#42]

I had my 97 locked in neutral. Couldn't get it out, and could only push it around if i pulled the clutch in. The gear seized on the shaft. I was told that stock clutch plates were aluminum and really contaminate oil and gears. I had to take mine to my engine rebuilder for disassembly, press off the gear off the shaft, cleaned up shaft and reassembled. $250 later, no problems. Not sure if its that simple for your buddy, but it sounds similar.

[Spider]

I had that problem with one of my Huskys. The dogs on the third gear cog were worn and would kick out the gear and jam the gearbox when power was applied. Third gear, its mate, and a shift fork solved the problem.

[KXcam22]

I had that exact problem with my 92.  What happened was that the shift fork on the end of the shift shaft had slid outwards enough to prevent shifting.  I slid it back into place and it never happened again.  I know this is not much help. Cam.

PS it did prove that the KX500 can get 3rd gear holeshots and win races using only 3rd.