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Discussion Starter #1 (Edited)
KLR600 and 2008 KLR650 transmission, side by side.


Input Sides.


The input shafts are similar, but not interchangeable. The first gears are integral to the shaft and have a different tooth count and gear pitch. The splines are the same, but the gears are 3-dog on the 600 and 5 and 6-dog on the 650, so you can't mix 'n match the gears.

Output Sides.


The splines are different and the 600 is a 3-dog while the 650 is a 6-dog. First gear is not splined but the dogs won't mesh, so no mix 'n match. Well, they will mesh but there is almost nos slack so I don't know if they would shift worth beans.

Ratio Comparison.


Tom
 

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Discussion Starter #3
Yup.

You can take the KLR600 input shaft and transplant it, along with the KLR600 first gear on the later output shaft.

The 3-dog KLR600 1st gear will mate with the later 6-dog 5th gear, but there is not a lot of slack. Maybe it would work in practice, but I don't know why someone would do it.

It was once possible, before the transmission went to a 6-dog configuration in '96 (that would have been on the 'grandpappy' transmission we don't have). Still not sure why someone would do that.

Tom
 

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Discussion Starter #4


Tom
 

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So the pre '87 transmissions had lower 1/2/3 gears and were effectively a wider ratio spread overall. I find that very interesting.
jj
 

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Tom, I looked up the 84 and 87 crank to clutch ratios. I thought that I remembered that the 96 and up was changed again? I don't find a tooth count on the ring gears on any parts look up site.
My 2003 OEM service manual gives basic engine specs for KL650-A1 '87 thru A9 '95, but not A10 1996 thru A17 2003 & up.

1984-1986 KL600 68/28 = 2.428
1987-1995 KL650 75/33 = 2.272

Am I correct in my math that the kick pedal driving back thru the clutch to the crankshaft would be Easier with the 600 gearing? But not quite the degree of rotation.

Tom, You may move this posting to KLR600/650 Clutch thread if it is more appropriate.
 

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Discussion Starter #7 (Edited)
The 2008 has a 75 tooth gear on the basket.

I believe the 600 should give easier kicking, but less rotation.

Somewhere I have information on the primary tooth counts. I'll try to find it.

Tom
 

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Discussion Starter #8
Paul, what I have is only the two ratios, 75/33 and 68/28.

Tom
 

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Hello,

maybe it's not directly to the topic, but I'll ask anyway...
I'm an owner of 1990 KLR 650 with very worn splines on transmission output shaft. Pinion is held there only by some metal plate (same system like on KLR 600 shown above) and not by nut. I tried to get a new output shaft as a spare part, but with no succes - they are no longer available, at least in my country.

So either I can get some worn shaft from ebay with the risk of the same failure in the future.
Or, for quite the same money, I can get input and output shafts + gears of the new type (where pinion is held by nut).

Now the question is, do those new type shafts fit into old engine cases? And how about shifting mechanism? I'm especially worried abouth the 4/5 shifting fork, because, according to the spare parts catalogue, it was produced in several versions during the years.

To be more specific, I found either 2008 shafts and gears, or 2012 complete transmission (shafts, gears, forks, rods, "drum" and "star" etc.).

Does anybody have experience with this type of retrofit?

Thank you for your anwers!

PS: sorry for my bad English
 

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Discussion Starter #10
@jenicks08,

The new transmission will fit in the old case. I am quite sure of this. The best option would be a complete transmission (shafts, gears, forks, rods, "drum" and "star" etc.). That way you do not have to worry about the shift forks.

How soon do you need to buy the 2012 transmission? By that I mean: if you don't buy it right now will it be gone soon? I could install a 2008 transmission in an old case to be absolutely sure there are no issues if that would help you.

PS: Your English is excellent.
 

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Tom, thank you your reply and wiliness.

How long would it take you to test the 2008 set?
I can hardly judge, how long will the 2012 set be available - it might be gone in few minutes, it might last for weeks...
 

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Discussion Starter #12
I've had it in the case before, but I'll pop it back in tomorrow morning. This will make sure that there are no issues with end-play and that sort of thing. I should be done within 15 hours from now.
 

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Discussion Starter #14
@jenicks08,

I am sorry, but I was wrong (and something in the back of my head is remembering this, and there were marks on the case showing I had tried this before).

Second gear will not fit in the recess in the early case. The difference in the diameter of the gears seems to be about 2.5mm. That is comparing a KLR600 second gear to the 2008 second gear, but that is a good comparison because the gear was a 17 tooth up to 1996. The thickness of the case in this area is about 4mm.

In order to make the later transmission work, you would need to remove about 1.25mm from the case.

I'm going to take some pictures to show you the area I am talking about.
 

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Discussion Starter #15

 

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So it looks to be doable with a die-grinder & plenty of patience. Toms info & pics are invaluable in these cases. :)
 
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Discussion Starter #17
Yeah, I'd do it. If I was going to split the cases to replace a bad input shaft I'd put a new transmission in there that didn't require the plate. With patience and care, there is enough meat on the case to make the larger gear work.

It is unfortunate that the later transmission is a 6-dog vs 3-dog and you can't just swap the second gear set.
 
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Tom, thank you for the info!
Even if grinding seem to be a solution, I guess I'll just hold on to old type transmission. Meantime, I found some non-used output shafts in Germany. So if the original one lasted for almost 30 years, this replacement is hopefully gonna serve longer than I'll be able to ride a bike :)
 

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Discussion Starter #19
Ah, new-old-stock is a good thing to find! We seldom find that on the really good stuff here in the US.


Good luck with the swap and let us know how it comes out!
 
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Would be nice if the 650 had kept the lower 1st gear. Would be easier on the clutch when starting off in soft stuff and on hills.
 
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