99' KLR 650 Will Not Shift - Kawasaki KLR 650 Forum
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post #1 of 3 Old 04-06-2016, 05:05 PM Thread Starter
Join Date: Apr 2016
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Exclamation 99' KLR 650 Will Not Shift

I replaced the springs and fibers in my clutch. The clutch feels like it's actuating properly and the bike starts and idles as it should. However, I cannot get it to go into gear. It feels like the shift peg is locked up or somethings and does not move at all . Anybody experienced this before?
wellsbrewer is offline  
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post #2 of 3 Old 04-06-2016, 08:08 PM
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 6,279
I find this totally odd! Did you play with/fiddle with the gear shift pedal with the clutch cover removed? If so, maybe you dislocated the 'flat metal' ratchet spring??
Do you have a proper service manual? Do you have access to a proper parts screen? www.kawasaki.com/ owner info., or bike bandit or ron ayers or rockymtn atv/mc.com?

Did you 'back-off' the cable adjusters. ie, 'Limp-lever' and then take adjustment up to 1/8th inch free slack?

Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #3 of 3 Old 04-06-2016, 08:32 PM
Pretty in Pink, dunno why
Tom Schmitz's Avatar
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,972
Some folks have reported that the transmission will not shift (acts like it is locked up) when the change lever spring breaks.

Since you were in the area, perhaps it got knocked loose.

It's part 92081 in the diagram below.

If yours is lost or broken, they are $3.22 from Partzilla.


Tom [email protected]

I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like. -Philip Marlowe

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

Sting like a butterfly.
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clutch replacement, will not shift

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