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.