Join Date: Nov 2009
Location: Lander, Wyoming
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.
Modify at "YOUR OWN RISK"!
Still riding my 1987 KL650-A1. 85,000+ miles & counting