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This is my first post, I have only had the bike a couple months and dont know if the doohickey has been done. anyways, I was riding my 1992 klr 650 with about 21,000 miles on it, cruising at about 50 mph and my transmission made a horrible metal on metal noise and I lost power. I pulled over, put it in first and limped it home a couple miles. Does anybody have any ideas on what it could be? thanks
 

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How does it sound idling in neutral? & when you bring the revs up?
 

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It seemed to run fine once I started moving again. i'll fire it up in a while and see how it sounds today.
 

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Raise the back wheel, motor off, put in gear and try and turn wheel by hand. Try each gear.

I'm just suggesting things I would try. I haven't heard of two many transmission failures but not sayin' it ain't possible. Hopefully some other more knowledgeable folk will chime in.
 

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I hope you can do that by asking the previous owner!

If not, here are a couple of threads that may help you:

http://www.klrforum.com/showthread.php?p=269633#post269633

http://www.klrforum.com/showthread.php?t=35354

Be careful with nasty noises. The transmission, as klr4evr points out, is relatively bullet proof. There have been reports of shift fingers breaking, but not much else.

The most concerning possibility is the upper balancer shaft bearing letting go. That can lead to all kinds of havoc, including having the balancer smack the transmission.

If you feel any unusual vibration or nasty noises, err on the side of caution and leave it shut off until you can find the source. There are some pictures on this forum about the worst case scenario, but that can wait.

Tom
 

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Ended up just draining the oil, and luckily there was no metal in there. I'm going to check the gears like klr4evr said and take it for a test ride tomorrow.
 

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There are a few things that can go wrong in there so heed Tom's advice as he has first hand experience. If you hear any noise at all shut it down. It can go from bad to worse quickly. You may not even need to test ride. If you can spin the wheels in each gear then start it up on the stand and shift into each gear.

Optionally remove the left side cover and see if anything is loose.
 

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+1

I'd be pulling the left side covers to check the rear balancer bearing and have a look at the Doo, chain guides, etc.

You may be able to find some signs by wrapping the clutch lever to hold the clutch disengaged, then spinning the transmission in each of the gears by means of the rear tire. Sometimes this will show symptoms not evident through turning in neutral or running in gear.

The problem with issues which have loud metallic symptoms is that they seldom self rectify and more often prelude imminent disaster. It would be too bad to destroy your engine cases or some other nasty outcome so we cautious types prefer to panic early and avoid the rush. I caution against further road tests unless you have eliminated the possibles which can be checked in the shop.



There are a few things that can go wrong in there so heed Tom's advice as he has first hand experience. If you hear any noise at all shut it down. It can go from bad to worse quickly. You may not even need to test ride. If you can spin the wheels in each gear then start it up on the stand and shift into each gear.

Optionally remove the left side cover and see if anything is loose.
 

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........... I was ........... cruising at about 50 mph and my transmission made a horrible metal on metal noise and I lost power. ........
Was that noise just one noise or did it continue to rattle, grind, clank until you got stopped?

What happened when you lost power? Did the engine die? Did it lock up? Did it freewheel like the clutch was slipping or the chain broke or the sprocket teeth bent over?
 
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