I am Joe's Transmission, and Joe's Transmission's Great Grandpappy - 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 20 Old 08-20-2016, 04:40 PM Thread Starter
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Arrow I am Joe's Transmission, and Joe's Transmission's Great Grandpappy

KLR600 and 2008 KLR650 transmission, side by side.


Input Sides.


The input shafts are similar, but not interchangeable. The first gears are integral to the shaft and have a different tooth count and gear pitch. The splines are the same, but the gears are 3-dog on the 600 and 5 and 6-dog on the 650, so you can't mix 'n match the gears.

Output Sides.


The splines are different and the 600 is a 3-dog while the 650 is a 6-dog. First gear is not splined but the dogs won't mesh, so no mix 'n match. Well, they will mesh but there is almost nos slack so I don't know if they would shift worth beans.

Ratio Comparison.


Tom
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Last edited by Tom Schmitz; 04-12-2017 at 09:19 AM.
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post #2 of 20 Old 08-21-2016, 02:36 AM
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Well, that blows the "KL 600 1st gear will go in a KLR 650" myth right out of the water!

Thanks for posting this.
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post #3 of 20 Old 08-21-2016, 10:36 AM Thread Starter
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Yup.

You can take the KLR600 input shaft and transplant it, along with the KLR600 first gear on the later output shaft.

The 3-dog KLR600 1st gear will mate with the later 6-dog 5th gear, but there is not a lot of slack. Maybe it would work in practice, but I don't know why someone would do it.

It was once possible, before the transmission went to a 6-dog configuration in '96 (that would have been on the 'grandpappy' transmission we don't have). Still not sure why someone would do that.

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post #4 of 20 Old 12-07-2016, 05:59 PM Thread Starter
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Tom

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


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post #5 of 20 Old 12-07-2016, 06:13 PM
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So the pre '87 transmissions had lower 1/2/3 gears and were effectively a wider ratio spread overall. I find that very interesting.
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post #6 of 20 Old 12-07-2016, 06:56 PM
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Tom, I looked up the 84 and 87 crank to clutch ratios. I thought that I remembered that the 96 and up was changed again? I don't find a tooth count on the ring gears on any parts look up site.
My 2003 OEM service manual gives basic engine specs for KL650-A1 '87 thru A9 '95, but not A10 1996 thru A17 2003 & up.

1984-1986 KL600 68/28 = 2.428
1987-1995 KL650 75/33 = 2.272

Am I correct in my math that the kick pedal driving back thru the clutch to the crankshaft would be Easier with the 600 gearing? But not quite the degree of rotation.

Tom, You may move this posting to KLR600/650 Clutch thread if it is more appropriate.

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post #7 of 20 Old 12-07-2016, 07:18 PM Thread Starter
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The 2008 has a 75 tooth gear on the basket.

I believe the 600 should give easier kicking, but less rotation.

Somewhere I have information on the primary tooth counts. I'll try to find it.

Tom

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Last edited by Tom Schmitz; 12-07-2016 at 07:42 PM. Reason: 'gear', not 'bear'
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post #8 of 20 Old 12-07-2016, 07:26 PM Thread Starter
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Paul, what I have is only the two ratios, 75/33 and 68/28.

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


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post #9 of 20 Old 01-15-2019, 08:19 PM
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Hello,

maybe it's not directly to the topic, but I'll ask anyway...
I'm an owner of 1990 KLR 650 with very worn splines on transmission output shaft. Pinion is held there only by some metal plate (same system like on KLR 600 shown above) and not by nut. I tried to get a new output shaft as a spare part, but with no succes - they are no longer available, at least in my country.

So either I can get some worn shaft from ebay with the risk of the same failure in the future.
Or, for quite the same money, I can get input and output shafts + gears of the new type (where pinion is held by nut).

Now the question is, do those new type shafts fit into old engine cases? And how about shifting mechanism? I'm especially worried abouth the 4/5 shifting fork, because, according to the spare parts catalogue, it was produced in several versions during the years.

To be more specific, I found either 2008 shafts and gears, or 2012 complete transmission (shafts, gears, forks, rods, "drum" and "star" etc.).

Does anybody have experience with this type of retrofit?

Thank you for your anwers!

PS: sorry for my bad English
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post #10 of 20 Old 01-15-2019, 09:04 PM Thread Starter
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@jenicks08,

The new transmission will fit in the old case. I am quite sure of this. The best option would be a complete transmission (shafts, gears, forks, rods, "drum" and "star" etc.). That way you do not have to worry about the shift forks.

How soon do you need to buy the 2012 transmission? By that I mean: if you don't buy it right now will it be gone soon? I could install a 2008 transmission in an old case to be absolutely sure there are no issues if that would help you.

PS: Your English is excellent.

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


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