I am Joe's Transmission, and Joe's Transmission's Great Grandpappy - Page 2 - 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 #11 of 20 Old 01-15-2019, 09:52 PM
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Tom, thank you your reply and wiliness.

How long would it take you to test the 2008 set?
I can hardly judge, how long will the 2012 set be available - it might be gone in few minutes, it might last for weeks...
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post #12 of 20 Old 01-15-2019, 10:33 PM Thread Starter
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I've had it in the case before, but I'll pop it back in tomorrow morning. This will make sure that there are no issues with end-play and that sort of thing. I should be done within 15 hours from now.

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post #13 of 20 Old 01-15-2019, 10:47 PM
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Thank you very much for your help, I really appreciate it!
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post #14 of 20 Old 01-16-2019, 12:50 PM Thread Starter
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@jenicks08,

I am sorry, but I was wrong (and something in the back of my head is remembering this, and there were marks on the case showing I had tried this before).

Second gear will not fit in the recess in the early case. The difference in the diameter of the gears seems to be about 2.5mm. That is comparing a KLR600 second gear to the 2008 second gear, but that is a good comparison because the gear was a 17 tooth up to 1996. The thickness of the case in this area is about 4mm.

In order to make the later transmission work, you would need to remove about 1.25mm from the case.

I'm going to take some pictures to show you the area I am talking about.

Tom [email protected]

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post #15 of 20 Old 01-16-2019, 01:00 PM Thread Starter
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Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #16 of 20 Old 01-16-2019, 01:36 PM
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So it looks to be doable with a die-grinder & plenty of patience. Toms info & pics are invaluable in these cases.

pdwestman
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post #17 of 20 Old 01-16-2019, 01:48 PM Thread Starter
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Yeah, I'd do it. If I was going to split the cases to replace a bad input shaft I'd put a new transmission in there that didn't require the plate. With patience and care, there is enough meat on the case to make the larger gear work.

It is unfortunate that the later transmission is a 6-dog vs 3-dog and you can't just swap the second gear set.

Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #18 of 20 Old 01-17-2019, 01:32 AM
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Tom, thank you for the info!
Even if grinding seem to be a solution, I guess I'll just hold on to old type transmission. Meantime, I found some non-used output shafts in Germany. So if the original one lasted for almost 30 years, this replacement is hopefully gonna serve longer than I'll be able to ride a bike
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post #19 of 20 Old 01-17-2019, 06:20 AM Thread Starter
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Ah, new-old-stock is a good thing to find! We seldom find that on the really good stuff here in the US.


Good luck with the swap and let us know how it comes out!

Tom [email protected]

“She went out slowly. The way she did it hadn’t been learned at business college.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte


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post #20 of 20 Old 01-21-2019, 12:43 PM
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Would be nice if the 650 had kept the lower 1st gear. Would be easier on the clutch when starting off in soft stuff and on hills.

Never pick a fight with an old man.. If he's too old to fight, he'll just kill you..
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