Transmission problems - 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 14 Old 04-19-2015, 01:36 PM Thread Starter
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Transmission problems

Hey guys, I just bought a used 2004 KLR and for some reason everytime I'm trying to go in 2nd gear it goes to neutral... wonder if it is a common problem on the KLR and what's the fix for that?

Thanks
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post #2 of 14 Old 04-19-2015, 01:59 PM
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Welcome to the forum.

Couple of folks have had similar problems recently. Try a forum search.

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

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post #3 of 14 Old 04-19-2015, 02:08 PM
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I am not a transmission expert but I would suspect it is something simple like an adjustment. Are you sure that you are giving it a good shove with your foot when going from 1st to 2nd? I have noticed that the KLR takes a good shove to shift. It is nothing like other bikes that I have owned.
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post #4 of 14 Old 04-19-2015, 02:12 PM Thread Starter
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as much as I can and it stills kicks in neutral... pretty annoying. It's not my first bike, I also ride a 98 Kawa Concours. God love Kawa bikes but need to find the problem on my KLR
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post #5 of 14 Old 04-19-2015, 03:03 PM
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The most likely and usual cause is that the lever is loose on the shaft.

Tighten it and see if it get's better, then order a new one because the splines on yours are going to be messed up and will soon fail.

Or, it is something else entirely.

I'm pretty sure it will be one or the other.

Tom

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post #6 of 14 Old 04-19-2015, 04:05 PM Thread Starter
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The lever is good, I've check already
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post #7 of 14 Old 04-19-2015, 04:24 PM
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You may have to pull the clutch cover and check the band spring, the pawls, and the star wheel for wear or damage.

If those are in good shape, then it's going to need splitting the cases to get into the forks and such.

Are you absolutely sure that the lever is not slipping on the shaft, even though it is tight? And I mean abso****inglutely sure, as in 'you've cleaned it and watched while you move the lever and it ain't slipping' sure?

Tom

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Last edited by Tom Schmitz; 04-19-2015 at 04:27 PM.
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post #8 of 14 Old 04-19-2015, 06:08 PM
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I will leave the technical smart folk talking to Tom, but I will say to anyone else who thinks THEIR KLR is hard to shift into second - the KLR is the first bike I've owned where preloading the shifter really makes a huge difference. Every so often I forget and it's definitely noticeable.

So, preload your shifters, kids.




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post #9 of 14 Old 04-19-2015, 06:10 PM
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On some bikes, not just KLR's, if one keeps upward pressure against the gear pedal as one re-engages the clutch, the transmission will 'click' into gear.
I do not know exactly why.

But on some of the Kawasaki Bayou ATVs with 5 speed foot shift transmissions, the problem was traced to the steel races of the needle bearings on the ends of the transmission shafts not being completely seated in the engine case bores. Therefore some gears didn't turn Freely Enough.

Check out "I am Joe's Crankcase" by Tom Schmitz, in '87-'07 section.

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post #10 of 14 Old 04-20-2015, 09:01 AM
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A shot in the dark, but having found the shift lever to be in good shape maybe try lowering it a notch or two to give your foot more leverage. I have to move my left foot forward to where my heel is on the peg for just about any bike I ride.
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