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				broken shifter
				Posted: Mon Aug 20, 2001 9:10 am
				by Daniel W. Hirschbiel
				Howdy folks,
 
 This is my first post to the group so any help and/or patience is 
 appreciated. I have a 97' 650 KLR and I thrash on it in some heavy woods 
 cover that likes to eat my shifters. This is my third shifter in about a 
 year and it's starting to annoy me to say the least. Does anyone know of an 
 aftermarket shifter that would hold up better than the OEM part. Each of 
 the shifters have broken right where the arm connects to the pinch block 
 that slides onto the shifter shaft. Looks more like a broken weld than 
 anything else. Thanks in advance.....
 
 
 Dan
 
			 
			
					
				broken shifter
				Posted: Mon Aug 20, 2001 9:15 am
				by squidwannabe@hotmail.com
				Look at this IMS shifter compared to stock ..
 
 
http://www.finishlinewest.com/ims_install.htm
 
  --- In DSN_klr650@y..., "Daniel W. Hirschbiel"  wrote:
 > Howdy folks,
 > 
 > This is my first post to the group so any help and/or patience is 
 > appreciated. I have a 97' 650 KLR and I thrash on it in some heavy 
 woods 
 > cover that likes to eat my shifters. This is my third shifter in 
 about a 
 > year and it's starting to annoy me to say the least. Does anyone 
 know of an 
 > aftermarket shifter that would hold up better than the OEM part. 
 Each of 
 > the shifters have broken right where the arm connects to the pinch 
 block 
 > that slides onto the shifter shaft. Looks more like a broken weld 
 than 
 > anything else. Thanks in advance.....
 > 
 > 
 > Dan 
 
			 
			
					
				broken shifter
				Posted: Mon Aug 20, 2001 9:23 am
				by rclarke@bd.com
				The IMS shifter is the way to go. It bends instead of breaking.
 
 -Rick
 
 
 
 
 
 squidwannabe@... on 08/20/2001 10:13:15 AM
 
 To:   
DSN_klr650@yahoogroups.com
 cc:
 Subject:  [DSN_klr650] Re: Broken shifter
 
 
 Look at this IMS shifter compared to stock ..
 
 
http://www.finishlinewest.com/ims_install.htm 
			 
			
					
				broken shifter
				Posted: Mon Aug 20, 2001 10:33 am
				by Vernon Cooke
				If you get a more rigid shifter, all the force could be transmitted to the
 shifter transmission shaft.  Is that what you really want?
 
 
 
 
 Vernon
 
 -----Original Message-----
 From: Daniel W. Hirschbiel [mailto:dwh3@...]
 Sent: Monday, August 20, 2001 7:08 AM
 To: 
DSN_klr650@yahoogroups.com
 Subject: [DSN_klr650] Broken shifter
 
 
 Howdy folks,
 
 This is my first post to the group so any help and/or patience is 
 appreciated. I have a 97' 650 KLR and I thrash on it in some heavy woods 
 cover that likes to eat my shifters. This is my third shifter in about a 
 year and it's starting to annoy me to say the least. Does anyone know of an 
 aftermarket shifter that would hold up better than the OEM part. Each of 
 the shifters have broken right where the arm connects to the pinch block 
 that slides onto the shifter shaft. Looks more like a broken weld than 
 anything else. Thanks in advance.....
 
 
 Dan
 
 
 Visit the KLR650 archives at
 
http://www.listquest.com/lq/search.html?ln=klr650
 
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DSN_klr650@yahoogroups.com 
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DSN_klr650-subscribe@yahoogroups.com 
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 List owner:  
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http://docs.yahoo.com/info/terms/ 
			 
			
					
				broken shifter
				Posted: Mon Aug 20, 2001 11:37 pm
				by mule2b@aol.com
				IMS and Moose both make an aftermarket shifter for the KLR. They are 
 both superior to the stock unit and of similar robust construction. They are 
 slightly different in shape, though. One of them is a good fit out of the 
 box, while the other needs to be ground down in one spot to clear the footpeg 
 on some shifts. I forgot which is which, but I believe the IMS is the one 
 with the better fit. Maybe someone else on the list knows off-hand.
 
      Steve
      "The Mule"
      A14
 
			 
			
					
				broken shifter
				Posted: Wed Sep 16, 2015 10:18 am
				by pwhatfourever@sbcglobal.net
				
Hey guys. The shifter just broke off my '06 KLR. I was noticing it was feeling soft, especially on downshifting. Before I could get out of traffic and pull over, I could no longer upshift from 1st. I was able to put it into second gear with a pair of channel locks and made it to the office. Plan to drive it home this afternoon on the backroads before rush hour.
It basically peeled of the hub of the shifter which remains on the tranny shaft.
Do I have it welded and if so, what type of welding? Can a muffler shop do it or do I need a specialist.
OR
Do I get a new shifter? Thanks!
 
			 
			
					
				broken shifter
				Posted: Wed Sep 16, 2015 10:33 am
				by Eddie
				 #ygrps-yiv-525615778  {margin:0.7em;}#ygrps-yiv-525615778 p {margin:0;}#ygrps-yiv-525615778 .ygrps-yiv-525615778OECFntDef {font-family:"Segoe UI", Tahoma, Verdana, Arial, Helvetica, sans-serif;font-size:10pt;}      
Are the splines on the shifter shaft coming out of the transmisson intact or at least somewhat intact? 
You could probably get away with a new shift lever tightened down well with a bit of Loctite on the bolt.
If the shaft splines are worn off, tack welding the shifter in place would be a band-aid fix at best. Keep in mind the heat of welding 
could wrec 
  
--- 
New Outlook Express and Windows Live Mail replacement - get it here: 
http://www.oeclassic.com/ 
  
k the rubber seal in the engine case. -eddie
..   Original Message:  
From: pwhatfourever@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> 
Reply-To: DSN_KLR650@yahoogroups.com>,  
To: DSN_KLR650@yahoogroups.com> 
Sent: 9/16/2015 11:18:00 AM 
Subject: [DSN_KLR650] Broken Shifter 
     
 
Hey guys. The shifter just broke off my '06 KLR. I was noticing it was feeling soft, especially on downshifting. Before I could get out of traffic and pull over, I could no longer upshift from 1st. I was able to put it into second gear with a pair of channel locks and made it to the office. Plan to drive it home this afternoon on the backroads before rush hour. 
 
It basically peeled of the hub of the shifter which remains on the tranny shaft. 
 
Do I have it welded and if so, what type of welding? Can a muffler shop do it or do I need a specialist. 
 
OR 
 
Do I get a new shifter? Thanks! 
 
			 
			
					
				broken shifter
				Posted: Wed Sep 16, 2015 10:47 am
				by Paul Whatley
				Thanks Eddie
As far as I can tell, the splines on the shaft are fine. The hub of the shift lever is still clamped onto the shaft. The shift lever cracked and broke free from its hub. My guess is the lever was cracked from dropping the bike.
Paul
        [b]From:[/b] "'Eddie' edgyver40@... [DSN_KLR650]" DSN_KLR650@yahoogroups.com>
 [b]To:[/b] "
DSN_KLR650@yahoogroups.com" DSN_KLR650@yahoogroups.com>; "pwhatfourever@..."  
 [b]Sent:[/b] Wednesday, September 16, 2015 10:33 AM
 [b]Subject:[/b] Re: [DSN_KLR650] Broken Shifter
   
                                      Are the splines on the shifter shaft coming out of the transmisson intact or at least somewhat intact? 
You could probably get away with a new shift lever tightened down well with a bit of Loctite on the bolt.
If the shaft splines are worn off, tack welding the shifter in place would be a band-aid fix at best. Keep in mind the heat of welding 
could wrec   --- New Outlook Express and Windows Live Mail replacement - get it here: 
http://www.oeclassic.com/   k the rubber seal in the engine case. -eddie
..   Original Message:  From: pwhatfourever@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> Reply-To: DSN_KLR650@yahoogroups.com>,  To: DSN_KLR650@yahoogroups.com> Sent: 9/16/2015 11:18:00 AM Subject: [DSN_KLR650] Broken Shifter       Hey guys. The shifter just broke off my '06 KLR. I was noticing it was feeling soft, especially on downshifting. Before I could get out of traffic and pull over, I could no longer upshift from 1st. I was able to put it into second gear with a pair of channel locks and made it to the office. Plan to drive it home this afternoon on the backroads before rush hour. 
 It basically peeled of the hub of the shifter which remains on the tranny shaft. 
 Do I have it welded and if so, what type of welding? Can a muffler shop do it or do I need a specialist. 
 OR 
 Do I get a new shifter? Thanks!                             #ygrps-yiv-785386646 #ygrps-yiv-785386646yiv1746503777 #ygrps-yiv-785386646yiv1746503777 --   #ygrps-yiv-785386646yiv1746503777ygrp-mkp { border:1px solid #d8d8d8;font-family:Arial;margin:10px 0;padding:0 10px;}  #ygrps-yiv-785386646 #ygrps-yiv-785386646yiv1746503777 #ygrps-yiv-785386646yiv1746503777ygrp-mkp hr { border:1px solid #d8d8d8;}  #ygrps-yiv-785386646 #ygrps-yiv-785386646yiv1746503777 #ygrps-yiv-785386646yiv1746503777ygrp-mkp #ygrps-yiv-785386646yiv1746503777hd { color:#628c2a;font-size:85%;font-weight:700;line-height:122%;margin:10px 0;}  #ygrps-yiv-785386646 #ygrps-yiv-785386646yiv1746503777 #ygrps-yiv-785386646yiv1746503777ygrp-mkp #ygrps-yiv-785386646yiv1746503777ads { margin-bottom:10px;}  #ygrps-yiv-785386646 #ygrps-yiv-785386646yiv1746503777 #ygrps-yiv-785386646yiv1746503777ygrp-mkp .ygrps-yiv-785386646yiv1746503777ad { padding:0 0;}  #ygrps-yiv-785386646 #ygrps-yiv-785386646yiv1746503777 #ygrps-yiv-785386646yiv1746503777ygrp-mkp 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				broken shifter
				Posted: Wed Sep 16, 2015 11:46 am
				by Mark Van Horn
				KLRs are well-known for that. Have it welded at some random garage. They should do it for $5 or less.
 On Wed, Sep 16, 2015 at 11:18 AM, pwhatfourever@... [DSN_KLR650] DSN_KLR650@yahoogroups.com> wrote:
                          
     
Hey guys. The shifter just broke off my '06 KLR. I was noticing it was feeling soft, especially on downshifting. Before I could get out of traffic and pull over, I could no longer upshift from 1st. I was able to put it into second gear with a pair of channel locks and made it to the office. Plan to drive it home this afternoon on the backroads before rush hour.
It basically peeled of the hub of the shifter which remains on the tranny shaft.
Do I have it welded and if so, what type of welding? Can a muffler shop do it or do I need a specialist.
OR
Do I get a new shifter? Thanks!      
   
         
  
			 
			
					
				broken shifter
				Posted: Wed Sep 16, 2015 11:57 am
				by GMac
				Common area for them to fail, right at the weld on the hub and arm.  You should have an idea how well the stock lever fit you.  There s longer, more offset or just stock.  You can take the hub off and have someone weld it for a temporary fix while you order one.  
 
  
 
 If you have vise grip pliers, you can clip that on the hub that s left to get you home.  Tricky shifting, but it gets you there.
 
  
 
 Greg McKinney
 CKCS Cavalier Rescue USA
  http://www.cavalierrescueusa.com/> 
www.cavalierrescueusa.com
 
 tnspanielrescue@...
 
  
 
 From: 
DSN_KLR650@yahoogroups.com [mailto:
DSN_KLR650@yahoogroups.com] 
 Sent: Wednesday, September 16, 2015 10:45 AM
 To: 
DSN_KLR650@yahoogroups.com; Eddie
 Subject: Re: [DSN_KLR650] Broken Shifter
 
  
 
 
 
 
 
 Thanks Eddie
 
  
 
 As far as I can tell, the splines on the shaft are fine. The hub of the shift lever is still clamped onto the shaft. The shift lever cracked and broke free from its hub. My guess is the lever was cracked from dropping the bike.
 
  
 
 Paul
 
  
 
   _____  
 
 From: "'Eddie' edgyver40@... [DSN_KLR650]" DSN_KLR650@yahoogroups.com>
 To: "
DSN_KLR650@yahoogroups.com" DSN_KLR650@yahoogroups.com>; "pwhatfourever@..."  
 Sent: Wednesday, September 16, 2015 10:33 AM
 Subject: Re: [DSN_KLR650] Broken Shifter
 
  
 
   
 
 Are the splines on the shifter shaft coming out of the transmisson intact or at least somewhat intact? 
 You could probably get away with a new shift lever tightened down well with a bit of Loctite on the bolt.
 If the shaft splines are worn off, tack welding the shifter in place would be a band-aid fix at best. Keep in mind the heat of welding 
 could wrec
 
  
 
 ---
 
 New Outlook Express and Windows Live Mail replacement - get it here:
 
 
http://www.oeclassic.com/
 
  
 
 k the rubber seal in the engine case. -eddie
 
 
 ..
 
 Original Message:
 
 From: pwhatfourever@... [DSN_KLR650] DSN_KLR650@yahoogroups.com>
 
 Reply-To: DSN_KLR650@yahoogroups.com>, 
 
 To: DSN_KLR650@yahoogroups.com>
 
 Sent: 9/16/2015 11:18:00 AM
 
 Subject: [DSN_KLR650] Broken Shifter
 
  
 
   
 
 Hey guys. The shifter just broke off my '06 KLR. I was noticing it was feeling soft, especially on downshifting. Before I could get out of traffic and pull over, I could no longer upshift from 1st. I was able to put it into second gear with a pair of channel locks and made it to the office. Plan to drive it home this afternoon on the backroads before rush hour.
 
  
 
 It basically peeled of the hub of the shifter which remains on the tranny shaft.
 
  
 
 Do I have it welded and if so, what type of welding? Can a muffler shop do it or do I need a specialist.
 
  
 
 OR
 
  
 
 Do I get a new shifter? Thanks!
 
  
 
 
 
 
 
 
 
 
 
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