Rebuilt - can not get into second - 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 1 Old 09-16-2018, 12:25 PM Thread Starter
1st Gear
Join Date: Aug 2018
Location: Winston Salem, NC
Posts: 20
Rebuilt - can not get into second

Hey everyone - I posted this at the end of an old thread but it seems time to start a new thread. We rebuilt my wife’s engine, as I wanted to learn more about the thing and we had to replace the bearing behind the clutch basket. I put everything back together and it is running great except that I only have 1st gear and neutral. The prawl spring is looking good and in place but with the right case off and while turning the wheel, I can’t get it to off neutral into second, and it won’t shift when put together and using the shifter/clutch either.

I’m thinking it has to be related to how I put the transmission back together (maybe carelessly put a fork in the wrong spot?). I hand-tested things as I went but who knows. So I need to pull the engine out again and break it all the way down I suppose. I am hoping someone might have some good starting places or lessons learned. Obviously if there’s anything I can do that doesn’t involve pulling the engine, I’d be stoked!

Thanks for any ideas you have
jsnfng is offline  
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