1989 transmission output shaft - 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 9 Old 07-21-2016, 01:39 AM Thread Starter
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1989 transmission output shaft

So I was replacing the chain and rear tire, and upon removing the forward chain guard, imagine my surprise when I see that the front sprocket has been WELDED onto the output shaft--and it's crooked, too! I'm debating whether to hunt down another output shaft (depends largely on what kind of prices I see for the part; the work is no problem) or having my rather more talented friend attempt the welding job a second time to see if he can produce a better result (I'm sure he would, but still would prefer the alternative if affordable).
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post #2 of 9 Old 07-22-2016, 12:03 AM
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OUCH!
Most owners would walk away.
Very time consuming to totally dis-mantle an engine and rebuild.

You might consider purchasing newer parts which use a NUT to retain the sprocket, instead of the 'twist-lock' and bolted retainer plate!

A little searching may yield the part numbers needed. Or maybe purchase an Entire Transmission cluster, even cheaper from 2008-2009 oil burner years.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 9 Old 07-22-2016, 11:08 AM
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I've seen that before; very unfortunate. :-(


Dave
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post #4 of 9 Old 07-23-2016, 09:58 PM
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I have one or two of the early transmissions on hand and a couple of new style ones. The complete transmission gear sets have to be swapped because the shafts and gears aren't compatible with one another.
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post #5 of 9 Old 07-23-2016, 10:18 PM
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Do the cases split horizontally? On my CB750s replacing the output shaft is far from a world ending task. Pull the engine, remove the lower engine case, swap it out, apply sealant and reverse.

Much more work if the cases split vertically, as then you have to take the top end down.
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post #6 of 9 Old 07-23-2016, 10:49 PM
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The cases split vertically. The shop time to do a swap is in the area of 13 hours, if memory serves.
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post #7 of 9 Old 07-24-2016, 02:51 AM
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Can a small weld be chiseled/ dremeled and the splines cleaned up right on the bike?

This is my son, with whom I am well pleased." ----God
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post #8 of 9 Old 07-26-2016, 12:14 AM Thread Starter
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Potentially. I worry about the condition of the shaft under the weld, though. It was probably so far gone that welding it was the only feasible option. KLR parts aren't exactly easy to come by in Taiwan. I am heading back to the States for a vacation soon, though, and I'll be able to grab all sorts of parts while I'm there and bring them back with me. I want to get doohickey parts and clutch plates, as well. I'm almost positive that the Taiwanese have no idea that the doohickey even exists, so I'm sure it'll need replacing.
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post #9 of 9 Old 08-20-2016, 03:18 PM Thread Starter
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Looking about for a replacement shaft... these buggers ain't easy to come by. Found a pair of shafts (input and output) on ebay from a 1985 that might work, but I'm not sure. Anyone got a spare output shaft lying about? Actually, I remember seeing something about a guy who had a destroyed engine from an old Tengai, and used the top end from it to restore an '08 engine. Wonder if he still has any parts from it....
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