2000 C5 gearbox seized! - 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 10 Old 08-16-2015, 05:55 AM Thread Starter
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2000 C5 gearbox seized!

Hi guys, I'm new to this forum. I've only had my thumper a few weeks. Was loving it until I was left at the side of the road last night!

I had done a hundred miles or so during the day and on the way home the engine started killing itself as if the cut off switch was faulty. After a few miles of intermittent miss firing the shifter stopped selecting 4-5th grear. I thought it was just a bent fork and carried on riding at reduced speed in third to limp it home. A further few miles and without warning the back wheel locked up completely. I clutched in and it didn't release the wheel. After coming to a reasonably controlled stop I tried starting her up and the engine runs (clutch in) but the back wheel is completely locked. The chain is fine, correct tension. So it's a gearbox issue. Has anyone encountered a similar problem.

Maki.
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post #2 of 10 Old 08-16-2015, 07:40 AM
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Sounds like a seized wheel bearing.

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post #3 of 10 Old 08-16-2015, 08:55 AM Thread Starter
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No, definately gearbox related. The wheel still rotates a few degrees either way taking up the chain slack.
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post #4 of 10 Old 08-16-2015, 09:02 AM
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Ouch, that sucks! Guessing something came apart in the transmission and is locking it up then... Not a common thing on the KLR's, transmissions are usually quite robust. I do recall someone having a gear shear a few teeth once but I can't remember all the details.

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post #5 of 10 Old 08-16-2015, 09:03 AM Thread Starter
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Don't know if I'm glad it's un common or upset because there's less info about fixing it lol
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post #6 of 10 Old 08-16-2015, 09:06 AM
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Found the thread! His trans didn't lock up though. Here's the thread if you want to have a look at it.
http://www.klrforum.com/2008-klr650-...nsmission.html

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post #7 of 10 Old 08-16-2015, 09:10 AM
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Oh! And welcome to the forum!

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post #8 of 10 Old 08-17-2015, 03:35 AM Thread Starter
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Thanks, sounds similar... Il post an update when I strip her down. Won't be for a couple of months.
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post #9 of 10 Old 08-17-2015, 01:34 PM Thread Starter
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Cheers,I'll keep posting as I find out what's up. out of country for a couple of months now unfortunately so its going to be a winter project.
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post #10 of 10 Old 08-18-2015, 05:44 AM
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I had 3rd gear fail on my '08 at about 70k miles. Bought a replacement bottom end from Eagle Mike. His comment on 3rd gear failing was that it wasn't unheard of. He knew of at least a few others that had failed. This may not be your problem and while rare not unheard of. Good luck with yours.
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