Transmission Will Not Engage - 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 41 Old 05-01-2016, 03:18 PM Thread Starter
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Transmission Will Not Engage

I have a 2014 KLR -2600 miles. We were two track and single track riding this weekend. A lot of clutch feathering - very muddy, rained 10" night before. I get stuck at the bottom of a ravine. Bike runs, but when I let clutch out, nothing happens. The neutral indicator shows the bike is out of neutral and that I can put it back into neutral. Side stand switch also recognizes that the bike is in gear or not. The problem is that when I let the clutch out - nothing - no rotation at the front gear. Seems hard to believe the clutch is burned up at that few of miles on a legendarily dependable KLR. No other noise to indicate major transmission failure. Any ideas?
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post #2 of 41 Old 05-02-2016, 01:35 AM
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I assume that the clutch lever action/effort seems normal? Does the clutch lever/ cable still have the normal amount of lever clearance as before the symptoms of not driving the rear wheel occurred?

No grinding noises? Does it act the same in second gear?

Are there any unusual noises when pushing in neutral, first or second gears?
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post #3 of 41 Old 05-02-2016, 02:22 AM
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Your description of your ride in the mud begs the question. Did this happen all at once? Did the clutch work fine one time and then then next time fail to transmit power or did it slowly get worse each time you had to slip it a lot?

Fortunately, if your clutch plates are fried, it is not too difficult to replace them and it gives you a chance to clean the trash out of the oil pump screen.

I can tell you that I have put over 100k miles on one KLR clutch and 30k on another and they are still working well. So, yes they are sturdy clutches in my experience.
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post #4 of 41 Old 05-02-2016, 07:32 AM
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Is the clutch lever on top of the right hand case moving through it's full travel?
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post #5 of 41 Old 05-02-2016, 07:46 AM Thread Starter
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No unusual noises and seems to be no different in each gear BUT no way to really tell. If in gear - so feel the "click" in the shifter, the neutral light goes off - still rolls. This happened all at once, no progressive deterioration. That's why I'm stumped.
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post #6 of 41 Old 05-02-2016, 07:48 AM Thread Starter
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Quote:
Originally Posted by twinjet View Post
Is the clutch lever on top of the right hand case moving through it's full travel?
Clutch feels completely normal, normal tension, normal travel.
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post #7 of 41 Old 05-02-2016, 07:49 AM Thread Starter
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Well, I may have to do this. Have Clymers, will travel (again, eventually). Looking for a complete clutch kit this am and whether any special tools are required.

Thanks
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post #8 of 41 Old 05-02-2016, 09:24 AM
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It's unlikely that you could have burned up a clutch so completely that it acts like it's in neutral all the time. I have abused the snot out of my clutch and gotten it home and apart and found .001" wear on the plates.

I don't think I've heard of someone wearing out a KLR clutch in less than 100,000 miles.

A sudden inability to get it out of neutral makes me think that you should take the clutch cover off and have a look at the change lever spring.

It's part 92081 in the diagram below.



If yours is lost or broken, they are $3.22 from Partzilla.

Tom

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post #9 of 41 Old 05-02-2016, 09:35 AM Thread Starter
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I too think either a spring or a snapped rod. Either way, hoping no debris damage.

Thanks
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post #10 of 41 Old 05-02-2016, 10:09 AM
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Tom, since the neutral light is going on and off in response to moving the shifter, the shift drum must be moving? That points to other than the spring.

It's so easy to pull the clutch cover to look that I'd pull it.
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