2008 gears grind shifting and always stalls bike - Kawasaki KLR 650 Forum
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Old 05-22-2018, 09:55 PM Thread Starter
1st Gear
 
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Join Date: May 2018
Location: Edmonton AB
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2008 gears grind shifting and always stalls bike

So I've been dicking around with this for a couple weeks and I can't find any info on this type of stall.
Its a 2008 KLR 650 with 46 000km on it. It ran last year when i put it away, but since starting it up this year I can't get it to shift.

Whenever I try to shift into first all I get is grinding as soon as Ive lifted the shift lever halfway to a shift, as soon as I fully click it in the bike stalls.

The bike doesn't jump, even if I try at 2000 RPM, it just dead stalls the motor immidiatly. This is happening with the clutch lever pulled and the clutch disengaged (I can roll the bike with ease)
If it was a car I would say it was a bad synchro... but this is the first time I've dealt with this style of clutch... and i've been told there is no synco lol.

SO the common problems Ive ruled out:

-Its not a stuck clutch, oil has been changed, clutch has been taken apart it disengages freely when the lever is pulled.

-The kickstand switch works fine.

-the outside shift fork on the drum (the one visible from the right side) is fine, the spring is good, the bike changes gears while not running without issue.


So what is left? Im stumped, even the dealership is saying if they take it they will have to do a complete engine tear down because they have no clue.

I'm hoping someone has dealt with this before and shed some light before I have to pay the dealer to replace all the guts in the bottom end of the motor to scatter shot fix the problem.
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Old 05-23-2018, 09:11 AM
2nd Gear
 
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Have you tried moving in 2nd or 3rd? Does it stall in those gears?
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Old 05-23-2018, 12:44 PM Thread Starter
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You cant get past first even with the clutch fully disengaged.

Even with the clutch pack removed it still grinds and hard stalls the engine when you attempt to move it into first gear while running

Last edited by TechNeck; 05-23-2018 at 12:48 PM.
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Old 05-23-2018, 01:01 PM
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This is interesting.

Please verify the following:

With the clutch cover off, the clutch pack removed, and the transmission in neutral, the clutch hub (the inner splined piece that the steels mount to) is free to spin.

I would also recommend disabling the safety switches; you don't want a flaky switch influencing your diagnostics. This can be done, reversibly, with a couple bits of wire: http://www.klrforum.com/2008-klr650-...ch-bypass.html It will take 10 minutes to do and may save some grief.
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Old 05-23-2018, 05:45 PM Thread Starter
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are we talking the steel shaft the clutch pulls on? that is free to rotate, the bearing it seats into rotates freely.

nothing else on the clutch assembly is free moving, at leaste not by hand
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Old 05-23-2018, 06:20 PM
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You said you had removed the clutch pack, which is the steel and fiber disks, from the clutch assembly. You said that without a clutch pack in place that it still stalled the engine. I'm trying to determine if the hub, the very center of the clutch, which is connected to the transmission input shaft, is rotating freely as it should.

A simpler question, have you removed the water pump and clutch cover?

If not, then your terminology is different from mine, and I'd suggest this:

Put the bike in neutral. Start the engine, pull the clutch lever in completely, and blip the engine hard several times. Let it idle and pull the clutch lever in and out several times. Pull the clutch lever in and blip the engine hard several times.

See if it now goes into gear without stalling the engine.
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“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -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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Last edited by Tom Schmitz; 05-23-2018 at 06:24 PM.
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Old 05-23-2018, 06:41 PM
4th Gear
 
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Two questions might help.
With the engine off can you roll the bike in neutral with the clutch NOT pulled?
With the engine off can you roll the bike in first with the clutch lever PULLED?
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Old 05-23-2018, 09:41 PM Thread Starter
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Quote:
Originally Posted by GoMotor View Post
Two questions might help.
With the engine off can you roll the bike in neutral with the clutch NOT pulled?
With the engine off can you roll the bike in first with the clutch lever PULLED?
yes and yes

I did have the cover off and the water pump removed.

As far as I could tell the inner rotates, the outer doesn't the saft your clutch leaver pulls outs also rotates freely and both bearings it rides on are good.
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Old 05-23-2018, 10:01 PM
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1) With the engine off can you roll the bike in neutral with the clutch NOT pulled?
2) With the engine off can you roll the bike in first with the clutch lever PULLED?

Quote:
Originally Posted by TechNeck View Post
yes and yes...............
1) tells me the engine, clutch and main shaft in the transmission all rotate together fine.
2) tells me the countershaft, chain drive and rear wheel all rotate together fine and that the clutch works.

It sure makes me suspect that the side stand switch and the clutch switch are not keeping a ground signal to the ignitor when the neutral switch ground signal is lost as you start shifting out of neutral.
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Last edited by GoMotor; 05-23-2018 at 10:03 PM.
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Old 05-23-2018, 11:03 PM Thread Starter
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yup got it... short higher up in the kick stand switch.... when i tested the switch itself with a multimeter it worked... but it doesn't matter if the wire is cut high up lol.
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