Spring clip location - 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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  • 1 Post By Trail Bike Rider
  • 1 Post By Belldriver
 
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post #1 of 7 Old 01-18-2020, 06:51 AM Thread Starter
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Join Date: Apr 2017
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Spring clip location

The bike has been running perfectly but I am now in the process of changing the water pump seals.
I managed to dig out part of the seal assembly but the oil seal was covered in rust and well stuck into the housing.
I removed the clutch housing and in doing so I heard something come loose and fall to the floor.
It's a horseshoe shaped spring steel clip 2.5cms x 2cms with one leg slightly longer than the other.
I've stared at the clutch side assembly but can't work out where this spring should go.

I would be really grateful if anyone can advise.

Many thanks,
James.
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File Type: jpg KLR650 spring.jpg (64.8 KB, 4 views)

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Last edited by Trail Bike Rider; 01-18-2020 at 06:56 AM.
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post #2 of 7 Old 01-18-2020, 08:51 AM
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Join Date: Jul 2014
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That spring fits in the shifter fork assembly. Sorry I don't have a picture. You might try looking at a parts breakdown from an online supplier like Rocky mountain atv/mc.
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post #3 of 7 Old 01-18-2020, 10:12 AM Thread Starter
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Thanks for that info, I'll now find an exploded view of that area.
Presumably I will not have to disassemble anything?

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post #4 of 7 Old 01-18-2020, 10:58 AM Thread Starter
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OK I've found out what it is. It goes on the end of the gear change mechanism which begs the question "why/how did it fall out from the clutch cover casing"?
I hope I can refit it from the clutch case side?
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File Type: jpg gearchange spring.jpg (19.3 KB, 5 views)
File Type: jpg gearchange spring2.jpg (49.3 KB, 5 views)
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post #5 of 7 Old 01-18-2020, 11:02 AM
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youtube.com/watch?v=nzsg_MtXHzE
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post #6 of 7 Old 01-18-2020, 11:03 AM
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post #7 of 7 Old 01-18-2020, 11:22 AM Thread Starter
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Join Date: Apr 2017
Location: Spain and Gibraltar
Posts: 82
Problem solved thank you all!
I saw the youtube video after I had taken the photo from my bike below.

It must have been displaced when I was removing the clutch casing past the footbrake.

Thanks again all for your help and patience.

James.
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File Type: jpg gearchange spring3.jpg (309.3 KB, 6 views)

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