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shifting problems ?
Posted: Wed May 21, 2008 8:54 am
by Terry Taylor
I have an '03 klr with the stock shift lever.The lever has 27000 miles on it and there is some play or looseness as it sits on the shaft.The splines that they attach to appear to be in good shape. Recently I have noticed my first gear shift is harder to engage. It also makes a more defined "clunk" sound as I shift down. Mechanically it seems fine as it goes through the other gears shifting up.Downshifting back to first requires a little more effort to find it.The clutch itself feels fine as there is no slipping of the clutch noticed.Do I simply need to replace a worn out shifter or is there a tranny problem lurking in my future?Any help or advice appreciated.
[Non-text portions of this message have been removed]
piston boot
Posted: Wed May 21, 2008 9:20 am
by albatrossklr
Friend Jacob,
I only possess the wisdom to say that disc brakes are not within my
scope of knowledge. I've worked on them but it was all trial & error
(mostly error)..
Keep well,
albatross
who knows the things he doesn't know
--- In
DSN_KLR650@yahoogroups.com, Jacobus De Bruyn
wrote:
>
> Friends,
> My friend mechanic Carlos was right, you disconnect
> the brake pedal from the master cylinder, and the
> master piston shifts abt 1 or 2 mm, and there is a
> sweet spot, and the oil just dribbles in, without
> pumping it. All this wisdom he shared with me during
> his lunch break, sitting on the garage floor, eating
> his rice and beans. He is a good friend, I donated my
> old CG Today 125 to him last year.
> Now then, I got pressure on the rear caliper, and
> pumped out the caliper piston. Then I cleansed it,
> took off the rubber boot. The groove on the piston had
> some rust, so I used some waterproof fine sandpaper.
> blah blah. The thing is that the rubber BOOT does not
> fit anymore. I think the heat treatment enlarged it??
> Anyhow, it seems about 6 mm to big or wide for the
> hole it is supposed to go into.
>
> Now I got to find out where to get this boot, might as
> well change the piston, there are some scratches on
> it. Who done it?
>
> All this junk reminds me more of a toy than of a 48
> horsepower powerful motorcycle, that can get you
> according to the latest tall stories, a good 115 miles
> per hour. It is just too vulnerable to my taste. But
> I am grateful for the six San Miguel beers a kind,
> merciful Philipino captain gave me.
> Boy, did I need them!
> Now I need ideas from the infinite wisdom latently
> available on this site, but seems a bit recalcitrant
> to come forth. It seems more a bike to talk about,
> than to ride, but that s just my take on it today, and
> may change again soon. Cool it, Jacostarica.
>
shifting problems ?
Posted: Wed May 21, 2008 9:38 am
by Fred Hink
Your shift lever should be tight to the shift shaft. If you have tightened it as much as you can and it is still loose, you can widen the slot that you clamp together by taking off your shift lever and hold it in a vice while you use a hacksaw to widen the slot.
If you get your shift lever tight to the shift shaft and you still have trouble downshifting, I would look at the weld on the clamp of the shift lever to see if it is cracked. This is a common problem. Replace the shift lever and make sure it is tight. This will solve your shifting problem.
You haven't recently added a skid plate have you? Sometimes the rear mounting clamp interferes with the shift lever causing trouble downshifting. Either relocate this clamp or leave it off.
Fred
http://www.arrowheadmotorsports.com
http://s1.zetaboards.com/arrowhead
----- Original Message -----
From: Terry Taylor
To:
DSN_KLR650@yahoogroups.com
Sent: Wednesday, May 21, 2008 7:54 AM
Subject: [DSN_KLR650] Shifting problems ?
I have an '03 klr with the stock shift lever.The lever has 27000 miles on it and there is some play or looseness as it sits on the shaft.The splines that they attach to appear to be in good shape. Recently I have noticed my first gear shift is harder to engage. It also makes a more defined "clunk" sound as I shift down. Mechanically it seems fine as it goes through the other gears shifting up.Downshifting back to first requires a little more effort to find it.The clutch itself feels fine as there is no slipping of the clutch noticed.Do I simply need to replace a worn out shifter or is there a tranny problem lurking in my future?Any help or advice appreciated.
[Non-text portions of this message have been removed]
[Non-text portions of this message have been removed]