KLE500 Gearbox / Gearchange advice?

[gdj444]

I have a 2005 Kawasaki kle500 with @8000 miles showing, great bike for my needs and thus far proved 100% reliable.

Recently noticed that when changing down it doesn't always find the gear, usually happens when changing from 6th to 5th, 5th to 4th or 4th to 3rd, not noticed it happening in any lower gears, when the problem arises there is no tension against the gear change lever so it just goes down but the gear change doesn't happen and stays in the gear i was in, sometimes I need to try 2 or 3 times before it changes gear, when it is behaving I can feel the tension on the gear lever prior to changing.

Seems to be getting more regular and was hoping for some advice, I have no mechanical ability so it will be a garage job but would be handy to know if I am going to need to save up!

Thanks in advance

Jonesy

[stinkwheel]

So the gear lever moves up/down as normal but doesn't seem to "catch"?

That sounds like it could be wear on or damage to the external gear selector mechanism but it seems a very low mileage for it to happen. Happened on my GPZ (same motor in that respect) but not until it had done over 60k miles.

So. First off check the clutch adjustment and also ensure you are allowing the gear lever to fully return after selecting each gear. Your toe should come fully off the lever. Often a problem when people buy new boots.

Failing that, I'd be looking at the primary gearshift which consists of two metal "hooks" which grip and rotate the selector drum when you move the lever. One hook pulls one way, the the the other way and they are joined together by a couple of small springs that make them engage in the slot on the selector drum.

The points on the hooks can be worm round so they don't catch properly or a spring can be broken so they pop out.

On the plus side, you can get at it without either dismantling the whole engine or taking the engine out of the frame. If anyone twells you this is the case, they don't know what they're talking about.

It's located under a seperate cover underneath the front sprocket. If you lean the bike over top the right, you don't even need to drain the oil. You do need a new paper gasket for the cover.

If it was me, I'd be whipping off the cover and inspecting it. You sometimes get away with simply filing the (surprisingly flimsy) hook back to a point or replacing the spring. You might need to replace the whole selector mechanism. The mechanism CAN be removed and replaced with the engine in the frame, I know because I've done it but it takes some jiggling about.

Right click, "view image" to see these full size.

https://www.bikechatforums.com/download.php?id=79385
https://www.bikechatforums.com/download.php?id=79384
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[gdj444]

Thanks , that is a great help, bike is due service and mot in February, not been done since I have had it so I will take your pictures down to my garage, I was planning to have chain and sprockets replaced and ask them to look at gear linkages at same time, still using old boots and have had a few bikes over the years so think problem is more mechanical than rider (unfortunately), thanks again

Jonesy