Stuck transmission - Kawasaki KLR 650 Forum
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Old 07-12-2013, 06:04 PM Thread Starter
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Join Date: Aug 2012
Location: Central Illinois for now
Posts: 28
Stuck transmission

First off I have a 2009 KLR with 6700 miles on it, never been crashed nor down. Now the story. I Was riding yesterday and as I was leisurely pulling away from an intersection I shifted to second then attempted to shift to third. No go! It was & is stuck in second gear. Shift lever is tight on the shaft, moves as it should but will not change the transmission. I say a YouTube video that describe this exact thing and the cause was the shifter change lever spring. I pulled the right side case to see whether that was the problem & the spring is fine.

Other than possible shift linkage problems behind the clutch, has anyone else had this problem & if so what was the cause & solution? Thanks for any & all advise.
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Old 07-12-2013, 09:21 PM
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Join Date: Nov 2012
Location: NE. Indiana
Posts: 17
I had the exact same thing happen to my 2012. Mine was the detent spring, it broke with just 500+ miles on it.
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Old 07-12-2013, 09:31 PM Thread Starter
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Join Date: Aug 2012
Location: Central Illinois for now
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I figured this can't be that rare of a problem, but i sure can't find very many references to it happening.
By "detent spring" are you referring to the flat spring shaped like a "C" on the right side in the lower left corner as you look at the right side of the bike or is it a different one? If is the one I described Kawasaki refers to that as the "shifter lever change spring".
By the way where in NE Indiana you located? Ft. Wayne?

Last edited by phila1114; 07-12-2013 at 09:34 PM.
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Old 07-12-2013, 11:39 PM
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Yes, same spring. Mine broke and fell off completely. Yes Fort Wayne.
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Old 07-13-2013, 07:08 AM Thread Starter
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Location: Central Illinois for now
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Thanks for the clarification.
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Old 08-16-2013, 01:22 PM Thread Starter
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Join Date: Aug 2012
Location: Central Illinois for now
Posts: 28
Update to stuck transmition

Problem turned out to be a broken dog on a gear in the transmition. Had to have the engine pulled & cases split to find it. The rest of the engine all looks great. The stock tension spring on the doohickey was loose but in place. Not doing anything but just hanging there. Replacing it w/EM torsion spring & doohickey. The balancer chain had not gotten into the cases. Also fixing the "deep hole" problem. Phil
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Old 08-16-2013, 02:35 PM
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Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
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Thanks philla, nice to know the cause. How much was the $$damage$$ if you don't mind?
Regards....justjeff

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Old 08-16-2013, 02:44 PM Thread Starter
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Location: Central Illinois for now
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Had to take it to the shop. Estimate is $8-900.
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Old 08-16-2013, 02:50 PM
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Join Date: Oct 2011
Location: Lac La Biche Alberta Canada
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Don't feel bad. At least it didn't pile up and destroy the whole engine!
Regards....justjeff

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Woooo WOOOOO!!!!!
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Old 08-25-2013, 11:56 AM Thread Starter
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Join Date: Aug 2012
Location: Central Illinois for now
Posts: 28
Got it back!

Problem was a broken "dog" off the "gear dog" in the gearbox. Didn't do any other damage to the engine or gearbox. Fact is the rest of the engine internals look like new. Part of the rebuild involved the install of the EM Doohickey, torsion spring & fixed the " deep hole" problem of the 2008-9 KLRs. Also did the valve & timing checks. Everything was good.
FYI, the factory Doohickey spring was still in place but was doing nothing. It is obvious that it was too long from the factory to do any kind of tensioning. I feel much more comfortable with the engine now that it has been replaced.
Total repair cost was a touch over $900 because I had the dealer do the Doo per the instructions from EM. Thanks Eagle Mike for the info & parts & thanks to Dave at my local shop for the co-operation & help. Phil
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