2007 KLR shifter problem solution??? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 6 Old 12-21-2013, 08:41 PM Thread Starter
Join Date: Sep 2013
Location: Las Cruces, NM
Posts: 13
Question 2007 KLR shifter problem solution???

So here is my dilemma, I am physically having a difficulty shifting "down & up" (missing the shift) with my full size boots. I dont have a physical issue with my left ankle. Just very hard and a pain in the rear to actually catch the rubber end of the shifter porperely, when shifting. I am considering "cutting & lengthening" and rewelding (mig welding) back the the original shifter into my happy spot.

Question is:

1) Has anyone done this mod?

2) Is it actually possible to "weld" back the shifter together on this stock metal shifter with a mig welder or is it made out of "pot metal", which I was told by a welding buddy that it wouldn't end up being a strong weld, if the stock metal is actually made out of "pot cast metal". It would really suck to attempt this mod, and end up with a weak shifter or a possible broken shifter/weld, out in the middle of no where...Thanks in advance for any replies.
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post #2 of 6 Old 12-21-2013, 08:55 PM
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Both IMS and Moose make a shifter that is 1" longer than stock. As an added benefit they have a folding tip and a disc to guard against punching the lever through the side case.

For $35 it's probably not worth your effort to modify the stock shifter. But, yes, it can be done.


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post #3 of 6 Old 12-21-2013, 09:09 PM Thread Starter
Join Date: Sep 2013
Location: Las Cruces, NM
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Thanks brother...Santa is picking it up right now!
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post #4 of 6 Old 12-21-2013, 09:33 PM
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The factory shifter is steel but was a known weak point on the Gen1 bikes and often broke at the clamp/beam weld. As Tom said get the aftermarket one and you will be very satisfied. I put an IMS shifter on both my Gen1 and Gen2 and would never go back.

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post #5 of 6 Old 12-21-2013, 11:50 PM
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Join Date: Oct 2013
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What Tom said, of course!

The stock levers weld quite well as have done some and seen lots of others welded. I like to use some silicone gasket material (RTV) to glue a section of steel plate into the recess in the side cover to reinforce the cover against having the end of the lever driven through the cover.

You're having a not unusual experience with shifter and boots.
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post #6 of 6 Old 12-22-2013, 12:00 AM
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Join Date: Apr 2013
Location: Western Montana
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Stock shifter is easy to weld, but does need to be beefed up where it joins the clamp. Also consider lowered/set back foot pegs.

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