bypassing clutch and sidestand idiot switches

[Randall Marbach]

I not only increased the gap on the "bolt side" of my IMS shifter, but I also took a hack saw blade and cut about a 1/4 inch gap on the "inside" of the shifter, making it a bit easiler for the bolt to cinch down on the shifter shaft. HTH Randy from Burbank ----- Original Message ---- From: Luke in Brooklyn To: kelly@...; a14@...; DSN_KLR650@yahoogroups.com Sent: Tuesday, April 3, 2007 7:05:28 PM Subject: Re: [DSN_KLR650] Can't shift into 1st or 2nd Kelly-- I ended up clearancing the "gap" in my aftermarket shifter to make it wider, using a cutting disc on the dremel carefully held in between... actually I may have used the cylindrical carbide cutter attachment, can't remember... then used a longer bolt--so long that it pokes out significantly on the far side. I made REAL sure it was how I like it, then cranked it WAY down with the super strong loctite on it. With the widended gap it grabbed really well. Then I dabbed on a bit more loctite and backed on a nyloc nut to the exposed threads of the too-long bolt, as a sort of double lock nut arrangement. That was almost 20k ago I'd say, and it's rock solid. If your splines are already trash you're SOL, but I was able to save it in time. Luke

> Okay, I checked. Turns out the shift lever bolt was > as tight as it > could go, and yet the lever was still loose on the > shaft. 1/3 of the > splines were stripped (or worn) off near the > mounting bolt. This is the > Dual-Star replacement shift lever.

Brooklyn NY 92 CB750 nighthawk--naked simpleton 03 KLR650--fat girl with a dirty mind ____________________________________________________________________________________ Get your own web address. Have a HUGE year through Yahoo! Small Business. http://smallbusiness.yahoo.com/domains/?p=BESTDEAL 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/dsnklr650 Yahoo! Groups Links ____________________________________________________________________________________ Get your own web address. Have a HUGE year through Yahoo! Small Business. http://smallbusiness.yahoo.com/domains/?p=BESTDEAL

[J. Christopher Krok]

> 4d. Re: Can't shift into 1st or 2nd > Posted by: "Kelly Cash" kelly@... balancedman1960 > Date: Tue Apr 3, 2007 5:44 pm ((PDT)) > > Apparently I must have a discussion with Dual Star. By not being able > to downshift to first in the gravel, I dropped the bike, breaking a > mount for my Jesse bags (which weren't on at the time). Cost me $40 to > get it welded out on the road.

I don't know if they'll do anything for you... The aftermarket shifters tend to have softer splines in general (there's a note in the FAQ), and I think Dual Star just takes someone else's and welds the washer onto it. But, good luck with them. C -- J. Christopher Krok, Ph.D. Big Cee Engineering KLR650 Accessories and home of the FAQ

[Norm Keller]

There are two "standard" methods to deal with this concern. 1) Permanently by-pass the switches. 2) My preference is to install a switch to allow the safeties to be by-passed when desired. Email if you would like a copy of the procedure for doing the second preference. Norm [Non-text portions of this message have been removed]