Wilsons Sandbox

Posted: **Wed Feb 20, 2013 8:21 am**

Well, after 31,950 miles and 13 years, I finally had a road breakdown on the '00 KLR. Lucky was just getting into my buddies driveway. Had shifted to 1st after he opened the gate and never could get it to 2nd gear. We played with it and finally got it back to Nu. Restarted bike , engaged 1st again and same, could not get into N or 2nd. On the trailer and back home. Sigh! As soon as it warms up outside, I'll pull the clutch side and see if the problem is in that section.

Posted: **Wed Feb 20, 2013 8:42 am**

Have you checked your shift lever to see if it might be cracked at the weld where you tighten to the shift shaft? Is this the stock OEM shift lever or aftermarket? I m betting OEM. Fred http://www.arrowheadmotorsports.com From: achesley43@... Sent: Wednesday, February 20, 2013 7:14 AM To: DSN_KLR650@yahoogroups.com Subject: [DSN_KLR650] Transmission Woes Well, after 31,950 miles and 13 years, I finally had a road breakdown on the '00 KLR. Lucky was just getting into my buddies driveway. Had shifted to 1st after he opened the gate and never could get it to 2nd gear. We played with it and finally got it back to Nu. Restarted bike , engaged 1st again and same, could not get into N or 2nd. On the trailer and back home. Sigh! As soon as it warms up outside, I'll pull the clutch side and see if the problem is in that section. [Non-text portions of this message have been removed]

Posted: **Wed Feb 20, 2013 10:07 am**

On Wed, 20 Feb 2013 14:14:42 -0000 "achesley43@..." writes:

> Well, after 31,950 miles and 13 years, I finally had a road breakdown > on the '00 KLR. Lucky was just getting into my buddies driveway. Had > shifted to 1st after he opened the gate and never could get it to > 2nd gear. We played with it and finally got it back to Nu. Restarted > bike , engaged 1st again and same, could not get into N or 2nd. On > the trailer and back home. Sigh! As soon as it warms up outside, > I'll pull the clutch side and see if the problem is in that section. >

<><><><><><> <><><><><><> I'll bet your pay check the Spring, Change Lever, part number 92081-1493 on the end of the shift shaft (right side of engine) broke. Cost at RonAyers.com is $2.86, MSRP is $4.60 and my local dealer wanted $6.99 for one. You can find out more in the Clymers Manual, M474-3, on page 148, figures 48, 49 and left side para 2. That's chapter six, Clutch, Gearshift Linkage and Lubrication System, if you have a different Clymer's manual. When the spring breaks the shifting pawl is no longer held in contact with the shift cam (often called a star) and you're stuck in whatever gear you were lucky enough to be in when the spring broke. You'll be pulling the right side cover off to get to it so might want to consider getting a new coolant pump gasket too. If you are careful you'll be able to reuse the right side cover gasket and won't mess up the coolant pump seals. This is also a wonderful opportunity to clean the oil pick up screen and install new coolant. I like Toyota Red Line. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650 . . ____________________________________________________________ Woman is 53 But Looks 25 Mom reveals 1 simple wrinkle trick that has angered doctors... http://thirdpartyoffers.juno.com/TGL3141/5124f4b28d26f74b27e86st02vuc

Posted: **Wed Feb 20, 2013 10:20 am**

I know some people say you can re-use gaskets, and they've had success with that. But the gaskets do compress when they're tightened. I never re-use engine gaskets, even if it's brand new and I just installed it last week. They aren't expensive, and it's cheap insurance on having to redo it again because of a leak. I will usually keep one extra gasket for each side of my bikes engines on the shelf, so when they're needed I don't have to order one. Ryan Phoenix, AZ Jeff Saline wrote:

> > > On Wed, 20 Feb 2013 14:14:42 -0000 "achesley43@... > " > achesley43@... > writes: > > Well, after 31,950 miles and 13 years, I finally had a road breakdown > > on the '00 KLR. Lucky was just getting into my buddies driveway. Had > > shifted to 1st after he opened the gate and never could get it to > > 2nd gear. We played with it and finally got it back to Nu. Restarted > > bike , engaged 1st again and same, could not get into N or 2nd. On > > the trailer and back home. Sigh! As soon as it warms up outside, > > I'll pull the clutch side and see if the problem is in that section. > > > <><><><><><> > <><><><><><> > > I'll bet your pay check the Spring, Change Lever, part number 92081-1493 > on the end of the shift shaft (right side of engine) broke. Cost at > RonAyers.com is $2.86, MSRP is $4.60 and my local dealer wanted $6.99 for > one. > > You can find out more in the Clymers Manual, M474-3, on page 148, figures > 48, 49 and left side para 2. That's chapter six, Clutch, Gearshift > Linkage and Lubrication System, if you have a different Clymer's manual. > > When the spring breaks the shifting pawl is no longer held in contact > with the shift cam (often called a star) and you're stuck in whatever > gear you were lucky enough to be in when the spring broke. > > You'll be pulling the right side cover off to get to it so might want to > consider getting a new coolant pump gasket too. If you are careful you'll > be able to reuse the right side cover gasket and won't mess up the > coolant pump seals. > > This is also a wonderful opportunity to clean the oil pick up screen and > install new coolant. I like Toyota Red Line. > > Best, > > Jeff Saline > ABC # 4412 South Dakota Airmarshal > Airheads Beemer Club www.airheads.org > The Beautiful Black Hills of South Dakota > 75 R90/6, 03 KLR650 > > . > . > __________________________________________________________ > Woman is 53 But Looks 25 > Mom reveals 1 simple wrinkle trick that has angered doctors... > http://thirdpartyoffers.juno.com/TGL3141/5124f4b28d26f74b27e86st02vuc > > > > No virus found in this message. > Checked by AVG - www.avg.com http://www.avg.com> > Version: 2012.0.2238 / Virus Database: 2639/5618 - Release Date: 02/20/13 >

Posted: **Wed Feb 20, 2013 10:27 am**

I would also measure the clutch springs while you're in there. Even if not quite past tolerance i'd get new ones. They're inexpensive to replace; Fred sells heavy duty and regular. Your plates are probably OK. In my experience the springs wear out first if they get weak, the plates will then wear out quickly. Bogdan From: Jeff Saline > Date: Wednesday, February 20, 2013 9:05 AM To: "achesley43@..." > Cc: "DSN_KLR650@yahoogroups.comDSN_KLR650@yahoogroups.com>" DSN_KLR650@yahoogroups.comDSN_KLR650@yahoogroups.com>> Subject: Re: [DSN_KLR650] Transmission Woes On Wed, 20 Feb 2013 14:14:42 -0000 "achesley43@..." achesley43@...> writes:

> Well, after 31,950 miles and 13 years, I finally had a road breakdown > on the '00 KLR. Lucky was just getting into my buddies driveway. Had > shifted to 1st after he opened the gate and never could get it to > 2nd gear. We played with it and finally got it back to Nu. Restarted > bike , engaged 1st again and same, could not get into N or 2nd. On > the trailer and back home. Sigh! As soon as it warms up outside, > I'll pull the clutch side and see if the problem is in that section. >

<><><><><><> <><><><><><> I'll bet your pay check the Spring, Change Lever, part number 92081-1493 on the end of the shift shaft (right side of engine) broke. Cost at RonAyers.com is $2.86, MSRP is $4.60 and my local dealer wanted $6.99 for one. You can find out more in the Clymers Manual, M474-3, on page 148, figures 48, 49 and left side para 2. That's chapter six, Clutch, Gearshift Linkage and Lubrication System, if you have a different Clymer's manual. When the spring breaks the shifting pawl is no longer held in contact with the shift cam (often called a star) and you're stuck in whatever gear you were lucky enough to be in when the spring broke. You'll be pulling the right side cover off to get to it so might want to consider getting a new coolant pump gasket too. If you are careful you'll be able to reuse the right side cover gasket and won't mess up the coolant pump seals. This is also a wonderful opportunity to clean the oil pick up screen and install new coolant. I like Toyota Red Line. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650 . . __________________________________________________________ Woman is 53 But Looks 25 Mom reveals 1 simple wrinkle trick that has angered doctors... http://thirdpartyoffers.juno.com/TGL3141/5124f4b28d26f74b27e86st02vuc [Non-text portions of this message have been removed]

Posted: **Wed Feb 20, 2013 12:12 pm**

Did check that Fred . The lever is a motion pro. I first thought that maybe I had just slipped on the spline but all was good and rotating the shift shaft into the engine. Andy

--- In DSN_KLR650@yahoogroups.com, "Fred Hink" wrote: > > Have you checked your shift lever to see if it might be cracked at the weld where you tighten to the shift shaft? Is this the stock OEM shift lever or aftermarket? I m betting OEM. > > Fred > http://www.arrowheadmotorsports.com > > > > From: achesley43@... > Sent: Wednesday, February 20, 2013 7:14 AM > To: DSN_KLR650@yahoogroups.com > Subject: [DSN_KLR650] Transmission Woes > > > Well, after 31,950 miles and 13 years, I finally had a road breakdown on the '00 KLR. Lucky was just getting into my buddies driveway. Had shifted to 1st after he opened the gate and never could get it to 2nd gear. We played with it and finally got it back to Nu. Restarted bike , engaged 1st again and same, could not get into N or 2nd. On the trailer and back home. Sigh! As soon as it warms up outside, I'll pull the clutch side and see if the problem is in that section. > > > > > > [Non-text portions of this message have been removed] >

Posted: **Wed Feb 20, 2013 12:42 pm**

Motion Pro doesn t make shift levers. It doesn t matter since you have checked this weld and the shift lever is positive to the shift shaft. Does the shift lever return to the neutral position or does is drop and stay there? There is a spring that returns the shift lever to the middle or neutral position. This spring may break or the pin that this spring centers itself from may have come out or broken. If that s not the problem then more than likely it is the spring that attaches the shift pawl to the shift drum that was mentioned earlier. Let us hear what you find out. Fred http://www.arrowheadmotorsports.com From: achesley43@... Sent: Wednesday, February 20, 2013 11:12 AM To: DSN_KLR650@yahoogroups.com Subject: [DSN_KLR650] Re: Transmission Woes Did check that Fred . The lever is a motion pro. I first thought that maybe I had just slipped on the spline but all was good and rotating the shift shaft into the engine. Andy

--- In mailto:DSN_KLR650%40yahoogroups.com, "Fred Hink" wrote: > > Have you checked your shift lever to see if it might be cracked at the weld where you tighten to the shift shaft? Is this the stock OEM shift lever or aftermarket? I m betting OEM. > > Fred > http://www.arrowheadmotorsports.com > > > > From: achesley43@... > Sent: Wednesday, February 20, 2013 7:14 AM > To: mailto:DSN_KLR650%40yahoogroups.com > Subject: [DSN_KLR650] Transmission Woes > > > Well, after 31,950 miles and 13 years, I finally had a road breakdown on the '00 KLR. Lucky was just getting into my buddies driveway. Had shifted to 1st after he opened the gate and never could get it to 2nd gear. We played with it and finally got it back to Nu. Restarted bike , engaged 1st again and same, could not get into N or 2nd. On the trailer and back home. Sigh! As soon as it warms up outside, I'll pull the clutch side and see if the problem is in that section. > > > > > > [Non-text portions of this message have been removed] > [Non-text portions of this message have been removed]

Posted: **Wed Feb 20, 2013 2:59 pm**

Was the return leaf spring that had broken. Parts ordered from Ron Ayers. Spring, gaskets and WP seals. Had an old gasket in stock that had been on the shelf for about 10 years but it was getting pretty hard.

Quite a bit cheaper than Bike Bandit. All else checked out just fine in there. Heck, at near 32,000 just getting broke in. LOL.

--- In DSN_KLR650@yahoogroups.com, Jeff Saline wrote: > > On Wed, 20 Feb 2013 14:14:42 -0000 "achesley43@..." > writes: > > Well, after 31,950 miles and 13 years, I finally had a road breakdown > > on the '00 KLR. Lucky was just getting into my buddies driveway. Had > > shifted to 1st after he opened the gate and never could get it to > > 2nd gear. We played with it and finally got it back to Nu. Restarted > > bike , engaged 1st again and same, could not get into N or 2nd. On > > the trailer and back home. Sigh! As soon as it warms up outside, > > I'll pull the clutch side and see if the problem is in that section. > > > <><><><><><> > <><><><><><> > > I'll bet your pay check the Spring, Change Lever, part number 92081-1493 > on the end of the shift shaft (right side of engine) broke. Cost at > RonAyers.com is $2.86, MSRP is $4.60 and my local dealer wanted $6.99 for > one. > > You can find out more in the Clymers Manual, M474-3, on page 148, figures > 48, 49 and left side para 2. That's chapter six, Clutch, Gearshift > Linkage and Lubrication System, if you have a different Clymer's manual. > > When the spring breaks the shifting pawl is no longer held in contact > with the shift cam (often called a star) and you're stuck in whatever > gear you were lucky enough to be in when the spring broke. > > You'll be pulling the right side cover off to get to it so might want to > consider getting a new coolant pump gasket too. If you are careful you'll > be able to reuse the right side cover gasket and won't mess up the > coolant pump seals. > > This is also a wonderful opportunity to clean the oil pick up screen and > install new coolant. I like Toyota Red Line. > > Best, > > Jeff Saline > ABC # 4412 South Dakota Airmarshal > Airheads Beemer Club www.airheads.org > The Beautiful Black Hills of South Dakota > 75 R90/6, 03 KLR650 > > . > . > ____________________________________________________________ > Woman is 53 But Looks 25 > Mom reveals 1 simple wrinkle trick that has angered doctors... > http://thirdpartyoffers.juno.com/TGL3141/5124f4b28d26f74b27e86st02vuc >

Posted: **Wed Feb 20, 2013 3:22 pm**

Fred's advice about the shifter is right-on-point. I looked down at my shifter by chance once and noticed that the stock shifter was cracked; and about to fail. I'd start there. BTW, I use my KLR as a daily rider and do no off road. So even with "normal" use, the shifter can fail. Eddie

--- In DSN_KLR650@yahoogroups.com, "Fred Hink" wrote: > > Have you checked your shift lever to see if it might be cracked at the weld where you tighten to the shift shaft? Is this the stock OEM shift lever or aftermarket? I m betting OEM. > > Fred > http://www.arrowheadmotorsports.com > > > > From: achesley43@... > Sent: Wednesday, February 20, 2013 7:14 AM > To: DSN_KLR650@yahoogroups.com > Subject: [DSN_KLR650] Transmission Woes > > > Well, after 31,950 miles and 13 years, I finally had a road breakdown on the '00 KLR. Lucky was just getting into my buddies driveway. Had shifted to 1st after he opened the gate and never could get it to 2nd gear. We played with it and finally got it back to Nu. Restarted bike , engaged 1st again and same, could not get into N or 2nd. On the trailer and back home. Sigh! As soon as it warms up outside, I'll pull the clutch side and see if the problem is in that section. > > > > > > [Non-text portions of this message have been removed] >

Posted: **Wed Feb 20, 2013 3:51 pm**

--- In DSN_KLR650@yahoogroups.com, Bogdan Swider wrote:

> > I would also measure the clutch springs while you're in there. Even if not quite past tolerance i'd get new ones. They're inexpensive to replace; Fred sells heavy duty and regular. Your plates are probably OK. In my experience the springs wear out first if they get weak, the plates will then wear out quickly. > > Bogdan

In heated agreement with Bogdan and his Albatross about checking the clutch while you have it tore down. Historically, the clutch is very robust; some have indicated it is an identical KHI application on a bike of greater HP as well. However, it will fail if you pile enough mud up in the swing arm before you clean it out! Sad story follows. grin. Did a clutch inspection after an arduous GDR ride, Fall-2010; riding partner blew up his clutch in the Great Basin, WY. = Mud beyond belief and our abilities. cough. short pictorial here: http://groups.yahoo.com/group/GreatDivideRide/photos/album/1190230325/pic/list titled Agony of Adventure Recieved excellent 'emergency' service in Riverton, WY. http://www.wildwestpowersports.com/ at no extra charge. We went to the top of the list, 'so that your vacation will not be ruined.' IVO of my partners clutch saga, I tore mine down after I returned from the trip as well; all fiber plates were in spec at ~30,000 smiles, one discolored metal spacer/shim, as I recall, all springs at min. or less. revmaaatin.

Wilsons Sandbox

[dsn_klr650] improving your klr

transmission woes

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transmission woes