KLR Won't Shift Up Out Of 2nd Gear - 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 16 Old 06-03-2014, 05:20 PM Thread Starter
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KLR Won't Shift Up Out Of 2nd Gear

Hi. I'm new to this forum but I figured I'd run my most recent problem by you for ideas/suggestions.

Bought an "assembled" bike-- '88 frame, early 90's motor. Rode it about 10 miles before handing over the cash. Seemed OK. Trailered it home about 800 miles. Finally got it plated and took it out. It is very reluctant to shift up out of 2nd gear. Like pushing your toe against a brick wall 80% of the time. A bit more luck from 3 to 4 and to 5. No way to predict when it will shift like butter and when it will just balk. When it "cooperates", the shifting feels entirely normal (I have another old KLR to compare it to).

I've not been able to find anything like this searching the forums.

Thanks.

John
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post #2 of 16 Old 06-03-2014, 05:41 PM
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Bump....
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post #3 of 16 Old 06-03-2014, 06:14 PM
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Have you checked to make sure there's no interference with the shift lever hitting the case?



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post #4 of 16 Old 06-04-2014, 06:15 AM
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There is a little horseshoe shaped spring on the gear selector arm that has been known to fail. That's probably the issue. Part is part #92081-1493, at least since 1984.

You may want to check this video. You have to start somewhere - hopefully without splitting cases.


The video is long. He get's to it at about the 14 minute mark.


.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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Last edited by klr4evr; 06-04-2014 at 06:25 AM.
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post #5 of 16 Old 06-04-2014, 09:07 AM Thread Starter
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I am on my way to check that spring. Thanks!
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post #6 of 16 Old 06-04-2014, 09:32 AM
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Where are you located Old-n-slo?? Maybe take the time to add that to your Profile info and post an in the Introduction area. Welcome to the forum.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

<--- Please fill in the 'Location' on your personal profile page. User CP/Edit Your Details

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post #7 of 16 Old 06-07-2014, 04:44 PM Thread Starter
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Quote:
Originally Posted by klr4evr View Post
You may want to check this video. You have to start somewhere - hopefully without splitting cases.
.
Many thanks for that lead. I watched the video and went to work. Unfortunately, some previous owner re-welded the foot peg bracket and I had interference trying to get the clutch cover off. It took raising the motor, a grinding wheel, a dremel tool, and HOURS to get the cover off. Along the way, I think I butchered the water pump gasket or o-ring (leaks oil from the w/p now).

Anyway, while reefing on the cover, the little spring fell to the floor. I think it may have popped off banging around in the back of the van. I put it back into place. Once I get gaskets, o-rings, etc. delivered, I will try it out on the road. Here in the garage, it seems to be shifting just fine!

Hoping for the best. Would like to leave for Alaska in 3 weeks.
--JohnD
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post #8 of 16 Old 06-07-2014, 06:56 PM
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Good to hear that you made some progress although it sounded that it was a little painful. Funny what you find when you need to do something.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

<--- Please fill in the 'Location' on your personal profile page. User CP/Edit Your Details

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post #9 of 16 Old 06-08-2014, 01:41 PM
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Hope you got it running and welcome.
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post #10 of 16 Old 06-11-2014, 11:21 PM Thread Starter
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Still waiting on gaskets. I hope this bike can make it to Alaska and back in 3 weeks. That's the intention. Should have had a real plan, though.
John
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