Stalls and Lurches When Putting In Gear - Kawasaki KLR 650 Forum
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post #1 of 68 Old 01-31-2016, 04:08 PM Thread Starter
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Stalls and Lurches When Putting In Gear

I have a 2009 KLR with 6k miles. After starting the bike up and letting it run for a while it stalls and lurches forward when placing the bike in gear. Every thing I read suggested the problem could be the side stand switch. I replaced the switch while having the bike jacked up to the point the rear wheel was off the ground. While still jacked up, I started the bike and placed it in gear. Everything worked great. However, once the bike was off the jack the problem persisted.
In short, as long as the rear wheel was not touching the ground everything was great. But once the tires were on the ground the bike stalled and lurched forward when placed in gear. So the side stand switch was not the problem... any suggestions?
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post #2 of 68 Old 01-31-2016, 04:27 PM
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If it only does this the first time you put it into first gear after it's been sitting, it's your clutch plates sticking together.

Before you put it into first gear, try simultaneously pulling in on the clutch and blipping the throttle while it's in neutral. This should serve to mostly release the clutch plates so the lurch isn't so jarring. It doesn't lurch when it's on the stand because the rear wheel isn't driving against anything.

Sometimes I use the afore-mentioned procedure. Sometimes I just rev it up, kick it into first and hang on.



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post #3 of 68 Old 01-31-2016, 05:31 PM
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Originally Posted by planalp View Post

Sometimes I use the afore-mentioned procedure. Sometimes I just rev it up, kick it into first and hang on.
OUCH, planalp. That is hard on transmission gear dogs.

HB_ART,
Proper procedure as planalp 1st suggested.
But I'll modify a smidge.
Squeeze and HOLD the clutch lever. Don't 'milk it'. Blip the throttle 3 times, idle to 2000-2500 rpm.
Let return to idle, snick it smoothly into gear. Never stomp on a gear pedal (hard on other parts).

Check lever / cable slack at 1/16th to 1/8th inch.

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post #4 of 68 Old 01-31-2016, 05:43 PM
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Yeah, I probably shouldn't do that. I've never tried just holding the clutch lever in instead of squeezing it. I'll give that a go.



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post #5 of 68 Old 02-01-2016, 09:39 PM
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You all could warm it up in neutral, shut it off, put it in gear and restart it.

Realistically the clutch likely needs adjustment. Even though mine may lurch a LITTLE neither my '03 or my'11 stall when put into first from neutral.

If the clutch plates are warped somewhat they may be grabbing even when the clutch is pulled in.

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post #6 of 68 Old 02-02-2016, 02:16 PM
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Quote:
Originally Posted by pdwestman View Post
OUCH, planalp. That is hard on transmission gear dogs.

HB_ART,
Proper procedure as planalp 1st suggested.
But I'll modify a smidge.
Squeeze and HOLD the clutch lever. Don't 'milk it'. Blip the throttle 3 times, idle to 2000-2500 rpm.
Let return to idle, snick it smoothly into gear. Never stomp on a gear pedal (hard on other parts).

Check lever / cable slack at 1/16th to 1/8th inch.
When the bike sits for a while with out running the oil is squeezed from between the clutch plates and they start to stick together a bit. The longer it sits the tighter the plates stick.

I generally use Pdwestman's method above. But, if I am still getting jumping when going into gear, then before I start the bike I put in gear and pull the clutch and rock the bike back and forth until I feel the clutch break loose and let the bike roll. Then I start it.
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post #7 of 68 Old 02-03-2016, 11:58 PM
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Yes to GoMotor.

If it's been parked overnight or longer I usually give the bike a shove with the clutch
pulled in and first gear engaged. Many times it doesn't want to roll at all after an
extended park. Once loose, good all day.

Otherwise there's never more than a smooth click during startup n' go.

Your scooter might be just fine. At 1,000 miles per year your bike has seen some
long periods of being parked. Dunno if that figures in or not.

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post #8 of 68 Old 02-04-2016, 08:52 AM
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Originally Posted by HB_ART View Post
I have a 2009 KLR with 6k miles. After starting the bike up and letting it run for a while it stalls and lurches forward when placing the bike in gear.
As others have stated, initial clutch plate adhesion remains a characteristic of a wet clutch.

The condition may be exacerbated by warped clutch plates. The clutch can be disassembled (5 bolts), and the metal plates laid on a flat surface (e.g., glass pane) to check for flatness. Warped plates should be replaced with true flat plates.

NOTE: Pay attention to the exact sequence of specific metal and fiber plates for re-assembly; although most may be interchangeable, one or two might not!
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post #9 of 68 Old 02-07-2016, 01:41 PM Thread Starter
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Stalls and Lurches When Putting In Gear

My original post was as follows:

I have a 2009 KLR with 6k miles. After starting the bike up and letting it run for a while it stalls and lurches forward when placing the bike in gear. Every thing I read suggested the problem could be the side stand switch. I replaced the switch while having the bike jacked up to the point the rear wheel was off the ground. While still jacked up, I started the bike and placed it in gear. Everything worked great. However, once the bike was off the jack the problem persisted.

Based on the responses, for which I am extremely grateful for, I have;
* Replaced the side stand switch
* Changed the oil and replaced the oil filter

One person suggested after the bike lurches and stalls I should keep the clutch lever pulled in and restart the engine. Normally the engine would restart this way, however, when I try to start the bike it just lurches forward without any attempt from the engine to start.

Does the latter information coupled with the information in my original post narrow or pinpoint the problem?

As always, I appreciate all the input everyone has given. The KLR owners are the greatest riders and individuals.
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post #10 of 68 Old 02-07-2016, 02:45 PM
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My suggestion is still the same as previously posted.
----------------------------------------------------------------------
When the bike sits for a while with out running the oil is squeezed from between the clutch plates and they start to stick together a bit. The longer it sits the tighter the plates stick.

I generally use Pdwestman's method above. But, if I am still getting jumping when going into gear, then before I start the bike I put in gear and pull the clutch and rock the bike back and forth until I feel the clutch break loose and let the bike roll. Then I start it.
--------------------------------------------------------------------------------------------------
The bike didn't lurch when you put it in gear with the wheel off the ground because the wheel was off the ground. The side stand switch will not cause the bike to lurch. It just keeps it from starting/running.

Instead of keeping the clutch lever in and trying to restart after a lurch/stall, KEEP THE LEVER IN AND ROCK THE BIKE UNTIL THE CLUTCH BREAKS LOOSE. Then restart it.
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