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Discussion Starter #1 (Edited)
My son just picked up an older 93 klx650. Has only had it about 3 weeks and now it has a tranny problem.
Symptons are its stuck in gear and wont go to neutral.
The shifter will click up and down but on the up stroke it seems.... to go to far?
The clutch will disingage. Any ideas what this might be before we split the cases? I dont hear any grinding noises and any thing else out of the ordinary. No problems with it up until then.

He says he shut it off in gear and then it wouldnt go in to neutral when he tried to fire it back up. It wont push start since its in like 3 or 4th?? gear.

Any one have a source for a decent parts diagram or manual.

Thanks in advance!
 

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Do you have the correct oil in it? ..
I would lift it so rear wheel is off ground milk crate works but bike life much better..

and get it in neutral.. see if it will start by itself.. if not you have other issues also..

take it one step at a time.. if not sure on what oil is in it.. drain and re do it.. with only approved oil for wet clutch .. check the battery for full charge? just do all over basic maintance and see if you can find the issue..
 

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Discussion Starter #3
Do you have the correct oil in it? ..
I would lift it so rear wheel is off ground milk crate works but bike life much better..

and get it in neutral.. see if it will start by itself.. if not you have other issues also..

take it one step at a time.. if not sure on what oil is in it.. drain and re do it.. with only approved oil for wet clutch .. check the battery for full charge? just do all over basic maintance and see if you can find the issue..

IMO Its not an oil issue
Have tried to get it into neutral and thats pretty much the problem, it wont go into neutral.

The battery is fine. That shouldnt effect the the tranny as far as I know?

Appreciate the help.

Anyone ever have one do this?
 

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Discussion Starter #6
Bent shift forks, been there, done that. Did he drop it on the left side?

well as far as I know, no. More than likely though yes I would say he layed it down. Pretty much what I asked him also. But the shift lever looks fine, not bent up or torqued

OK so if you have fixed this one do I need to split the cases to get to the shift fork? I have never had a Kaw apart and the online diagrams I have found dont show the whole case so its tough to tell.

Any help with online diagrams or just hints would be great!
 

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Discussion Starter #7
Pulled the right side cover last weekend. Well the shift drum was NOT exposed so now I'm at a loss. Just for grins I ordered a repair manual online on Saturday so hopefully that will shed some more light on whats involved in fixing it.

On the upside it will at least get an oil change along with filter once it gets fixed :)
 

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When you had the right side case off did you notice the flat spring on the lower left? If it is not there then you need to find it then replace it within a new one. This spring is the shifter change lever spring. It holds the external shift fork up to engage the linkage that changes the transmission. If it is in place & functioning correctly then your next step is to remove the clutch basket & check the linkage behind it. If that is all working correctly then you will probably have to split the cases. Good luck & let's hope it is just a weak spring.
 
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