Shifer issue question - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 7Likes
  • 6 Post By Tom Schmitz
  • 1 Post By DPelletier
 
LinkBack Thread Tools Display Modes
post #1 of 6 Old 05-04-2020, 08:42 PM Thread Starter
Neutral
 
Join Date: Apr 2020
Posts: 12
Shifer issue question

Looking for a little help/advice. I have a 2006 KLR originally with a locked up engine. It had been sitting for a few years. Luckily I got the engine broke free and took off the clutch cover to check the clutches for stuck plates (no problem there), am rebuilding the varnished up carb, good there. Then when I went to put the trans in gear to hold the engine while torquing the impeller shaft, I discovered that I could not get the trans in any gear. I have rolled the tire while pushing down or lifting up the shifter pedal, no movement (it moves up and down freely but will not shift the trans into 1st or 2nd). I even pulled in the clutch pedal while pushing and pulling the shifter and rolling the wheel, again no luck. Before I pull anything else apart, I want to make sure the trans will go into gear.
This may sound stupid (since I normally work on the old Kaw 900 and 1000's), but it does not need to be running and spinning the disc packs to shift??? Sorry for being lengthy, but I wanted to give a little background. Thanks for any advice!
Barn Find KLR650 is offline  
Sponsored Links
Advertisement
 
post #2 of 6 Old 05-04-2020, 10:38 PM
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 8,095
Garage
Check the pawl spring on the clutch-side of the shift shaft. You may have knocked it loose when playing on the clutch side or it may just be broken.

No, the engine doesn't need to be turning in order to shift the transmission, but the transmission does have to be turning. Rolling the bike counts, as it spins the output shaft.

This is the pawl spring on the shift shaft (you thought I was going to leave you hanging with that jibberish, din'tcha?).



You should also check to see if the star-shaped cam that the pawl engages with is in good shape. That is what turns the drum, which moves the forks, which move the gears and results in a gear change.
foo, pdwestman, DPelletier and 3 others like this.

Tom [email protected]

“On the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again.” -Philip Marlowe

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

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 05-04-2020 at 10:42 PM.
Tom Schmitz is offline  
post #3 of 6 Old 05-05-2020, 08:29 AM
1st Gear
 
Join Date: Nov 2019
Location: Liberty, SC
Posts: 71
Also check the shifter itself. The early Gen1s had a tendency to crack near where they attach to the shaft. i forget which year that they beefed them up but I remember thinking that my '07 had the better shifter.

sre
StevenE is offline  
 
post #4 of 6 Old 05-05-2020, 10:08 AM
5th Gear
 
Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,833
Quote:
Originally Posted by StevenE View Post
Also check the shifter itself. The early Gen1s had a tendency to crack near where they attach to the shaft. i forget which year that they beefed them up but I remember thinking that my '07 had the better shifter.

sre
yep, they upgraded the shifter in '07.....it was about the only change since 1996 except color!

Dave
Barn Find KLR650 likes this.
DPelletier is offline  
post #5 of 6 Old 05-05-2020, 10:43 PM Thread Starter
Neutral
 
Join Date: Apr 2020
Posts: 12
Tom - Thanks for the info and the pic. If no one had a good guess, I was going to take the clutch cover back off (I looked into my manual and saw the shifter mechanism behind the clutch cover (which I just put on a new gasket and checked the fiber discs). I will tear it back off tomorrow and take a look see. THX!
Barn Find KLR650 is offline  
post #6 of 6 Old 05-05-2020, 10:45 PM Thread Starter
Neutral
 
Join Date: Apr 2020
Posts: 12
Thanks, I will check that out too!
Barn Find KLR650 is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome