1st gear grinding??? - 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 9 Old 05-12-2014, 11:05 PM Thread Starter
1st Gear
 
Join Date: Oct 2013
Posts: 31
1st gear grinding???

When I try and shift into first gear at a stop all I get is grinding - won't shift into first the vast majority of the time. Sometimes if i kick it hard it will go into first. If I want to take off I need to shift into second. It does not grind if I am shifting into any other gear. I can also downshift to first if I am moving. Only when I am at a stop does it grind. Also, I just put on a new clutch cable. I adjusted the nuts back and forth to see if this would help but it did not. Any ideas???
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post #2 of 9 Old 05-13-2014, 12:37 PM
2nd Gear
 
Join Date: Mar 2011
Location: San Pedro, CA
Posts: 129
Did this start with the installation of the new clutch cable? If so then I'd guess you need to properly adjust for the new cable. The goal is to have about an 1/8" of free play at the lever. You can get this by first adjusting the play at the end nearest the engine then fine tuning it with adjuster at the lever.
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post #3 of 9 Old 05-13-2014, 05:30 PM Thread Starter
1st Gear
 
Join Date: Oct 2013
Posts: 31
Fairly close. I adjusted the two nuts on the adjustment thread and moved it from one side to the other - close to both extremes - and it did not seem to make a difference. I originally set it up for about 1/8" play. I will take it back to that level and make sure I am still getting the grinding noise.
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post #4 of 9 Old 05-14-2014, 01:12 AM
4th Gear
 
Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
When did the grinding symptom begin?

Most likely is a dragging/not fully releasing clutch.
Cable adjustment, linkage wear/bent.
Warped clutch plates or friction material flaking off can have the same effect because the clutch doesn't fully release.

Grooves worn in the clutch basket fingers or drum spline are other possibles.

Knowing when this began might help to offer suggestions.
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post #5 of 9 Old 05-14-2014, 10:27 AM Thread Starter
1st Gear
 
Join Date: Oct 2013
Posts: 31
It started about a week ago - I put on a new clutch cable about a month ago and did not notice anything wrong at the beginning. Don't think the two are tied together - meaning that it did not start with the new clutch cable. I adjusted the cable at the motor to give myself about 1/8" free play at the lever. I confused myself on which way to loosen/tighten the adjuster nuts so I went to each extreme and then settled somewhat in the middle to get the 1/8" free play at lever.
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post #6 of 9 Old 05-14-2014, 02:19 PM
4th Gear
 
Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
I have encountered a few cables which began to stretch after a bit of use. Just a thought. I don't use a KLR clutch cable because I consider the original size cable to be undersized. I adapt a Yamaha ATV cable #5X6-26341-00; Motion Pro #306-5029.

It can be difficult to gauge whether the cable is stretching/giving but awareness of the possibility is step one.

More likely is warped clutch plates or grooves in basket/hub, IME.
HIH
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post #7 of 9 Old 05-15-2014, 08:32 AM
2nd Gear
 
Join Date: Sep 2013
Posts: 387
Shifter fork test

If from a stop it grinds going to 1st but shifts ok going to 2nd, you may have a bent shifter fork in the transmission.
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post #8 of 9 Old 05-15-2014, 12:08 PM
4th Gear
 
Join Date: Oct 2013
Location: Chilliwack, BC, Canada
Posts: 1,481
Thanks for that point, twinjet. I face palmed because I didn't think to ask whether the transmission grinds when stopped and attempting to engage second gear. I just assumed that the OP had checked this...

Sometimes I dispair at how muddled is my thinking. Wish there was a "hat's off smiley" to offer you.


Quote:
Originally Posted by twinjet View Post
If from a stop it grinds going to 1st but shifts ok going to 2nd, you may have a bent shifter fork in the transmission.
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post #9 of 9 Old 05-15-2014, 12:20 PM
2nd Gear
 
Join Date: Sep 2013
Posts: 387
I had a Yamaha 175 dirt bike with the same problem. Unfortunately getting to the shifter fork for inspection / replacement is not easy.
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