Gen 1 Gearbox output shaft interchangeability - 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 4 Old 09-01-2019, 12:17 PM Thread Starter
1st Gear
Join Date: May 2019
Location: Lake Macquarie, NSW, Australia
Posts: 37
Gen 1 Gearbox output shaft interchangeability

I am currently rebuilding a1990 Gen 1 gearbox. It has the old style sprocket retaining system (ie the retaining plate) on the output shaft and I notice the splines, whilst still usable, are now quite worn.

I have found a new old stock output shaft P/n 13128-1203 advertised. This has the later locknut securing system and is stated as being for 1995-2003 model years.

Anyone know if I can swap this in place of the existing shaft, simply transferring the existing gears across?

Many thanks

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post #2 of 4 Old 09-01-2019, 03:02 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,243
I believe that I remember reading that the splines on the internal portion of the shaft & gears is different.

The information you need should be in this link,

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 4 Old 09-01-2019, 03:04 PM
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Join Date: Feb 2009
Location: Redondo Beach
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As a drop-in replacement, no.

You would need to swap the entire transmission, gears and all, to go with the shaft. Unfortunately, the later model 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. It's probably doable, it just depends on how big your balls are and whether or not they are fully polished brass.

For more transmission information, see

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post #4 of 4 Old 09-01-2019, 04:29 PM Thread Starter
1st Gear
Join Date: May 2019
Location: Lake Macquarie, NSW, Australia
Posts: 37
Thankyou to you both for the quick and informative replies. For the benefits I'll gain I don't think I want to go to the effort of sourcing a complete gear cluster and then grinding away at the crankcase (especially as I'm working away from home in a borrowed workshop with a limited suite of borrowed tools). The splines on the old shaft suddenly don't seem too bad! I reckon they still have a good few miles in them so I'll take the risk and put it back in.

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