Wilsons Sandbox

First thought would be a cracked weld on the shift lever..... its a common problem according to the FAQ. HTH Randyy from Burbank ----- Original Message ---- From: Lamar To: DSN_KLR650@yahoogroups.com Sent: Sunday, January 18, 2009 2:58:47 PM Subject: [DSN_KLR650] transmission trouble - could use a clue I've been starting it and running it around the block the last weeks just to keep the battery up, but today was too nice not to ride. I got a few blocks away and tried to shift from 2nd to 3rd. It felt like I missed the shift. No problem, just clumsy, I thought. I tried again but 3rd wouldn't engage. I was coasting to a stop, so I tried to click down to 1st. Nothing happened! I rode back home in 2nd. The shift lever goes up and down as it should, but it won't take a gear with it. I have never had this happen on ANY bike and therefore have no experience in a tranny. WHAT has happened? Does this sound familiar to anyone??? SOS!!! Thanks in advance. Lamar A14 ------------------------------------ List sponsored by Dual Sport News at: www.dualsportnews.com List FAQ courtesy of Chris Krok at: www.bigcee.com/klr650faq.html Member Map at: http://www.frappr.com/dsnklr650Yahoo! Groups Links

--- In DSN_KLR650@yahoogroups.com, "Lamar" wrote:

> > I've been starting it and running it around the block the last weeks > just to keep the battery up, but today was too nice not to ride. I > got a few blocks away and tried to shift from 2nd to 3rd. It felt > like I missed the shift. No problem, just clumsy, I thought. I

tried

> again but 3rd wouldn't engage. I was coasting to a stop, so I tried > to click down to 1st. Nothing happened! I rode back home in 2nd. > The shift lever goes up and down as it should, but it won't take a > gear with it. > > I have never had this happen on ANY bike and therefore have no > experience in a tranny. WHAT has happened? Does this sound

familiar

> to anyone??? SOS!!! > > Thanks in advance. > > Lamar > A14 >Lamar,

The shifter is attatched to a shaft by compressing a splined female receiver over the engine shifter-shaft. 0) Mark the shifter on the input shaft so you will know where it goes later 1)Check to see if the bolt that attaches the shifter to 'shift-shaft' is tight. Clean the area around the splined shaft and 2)look at the receiver and shaft splines carefully with a flashlight or trouble light. Many report a failure to shift--to discover that it is actually a 'shifter failure to be tight' problem. It might be that the splines are now stripped and will not grip the shaft--but most likely 3)you can just tighten the bolt. IF that is the problem, clean the shaft and shifter receiver thoroughly before reattaching 4) you can make a tighter fit by using a fine tooth hack saw blade to open the 'pinch' of the shifter's compression fitting just a slight amount. By doing this, you will allow the bolt to compress the fitting a little bit more. 5)Be careful to NOT over tighten the bolt. Let us know if that is the problem. Otherwise, you will likely need a KLR-internist to solve your problem. 6)Get a second set of eyes on it before you do anything drastic. revmaaatin.

Check for a loose/broken shifter lever. Many have had the welds break on them. I pulled mine off and brushed off the paint to inspect the weld which to me was fine, then I welded on a large flat washer to the backside of the tip (like Dual-Star's have) and repainted it. Rather have the shifter weld fail than bend the shaft it sits on in the likely event of a tipover, wipeout. Dooden A15 Green Ape

--- In DSN_KLR650@yahoogroups.com, "Lamar" wrote: > > I've been starting it and running it around the block the last weeks > just to keep the battery up, but today was too nice not to ride. I > got a few blocks away and tried to shift from 2nd to 3rd. It felt > like I missed the shift. No problem, just clumsy, I thought. I tried > again but 3rd wouldn't engage. I was coasting to a stop, so I tried > to click down to 1st. Nothing happened! I rode back home in 2nd. > The shift lever goes up and down as it should, but it won't take a > gear with it. > > I have never had this happen on ANY bike and therefore have no > experience in a tranny. WHAT has happened? Does this sound familiar > to anyone??? SOS!!! > > Thanks in advance. > > Lamar > A14 >