Kawasaki KLE 500 1991 transmission

[zoombini]

https://photos.app.goo.gl/GrVgcn6MjADMGwdd8

https://photos.app.goo.gl/SFz6Ki3ZY7akUT2r7

https://photos.app.goo.gl/rGN9KwdpidYP8ppw8

New problems…

The bit marked in blue came undone. Since putting it back on the shaft and tightening it, I can’t get the bike out of neutral.

The bit circled in red is has tention pushed up (toward 2nd) but no tention / no where to go when pushed down (toward first).

I guess the thing marked in red needs to be positioned / before the bit marked in blue is tightened or I have it completely wrong.

NB the bits marked in green premuably fell off when it came undone on the road and could not be found.

Any help appreciated. As you can see in the last photo I’m illegally parked outside a Portuguese cafe in camberwell.

Best wishes

https://photos.app.goo.gl/GrVgcn6MjADMGwdd8

https://photos.app.goo.gl/SFz6Ki3ZY7akUT2r7

https://photos.app.goo.gl/rGN9KwdpidYP8ppw8

[Nobby the Bastard]

That pedal looks a little too low down. Undo it, remove blue bit from shaft, get red bit more level with the footrest and then put the blue bit on.
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Sprint ST 1050

[sickpup]

Have you tried with the engine running?

[rpsmith79]

The Blue Part is on a slipned shaft, my guess it that when you took it off/replaced it, you didn't put it back in the correct orientation

Like Nobby suggested, take it off again and retate it slightly onto a different spline, then try again, if that fails, try the next spline, etc, etc, etc until it works
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Current Bike: Honda CG125 ES4 // Honda CB600FS Hornet // Triumph Street Triple R

[zoombini]

Thanks team!

Yes tried with engine running.

Now I have a dedicated 10mm spanner rather than the socket set that didn’t fit and the adjustable.

Trying the spline method now! It makes sence to me.

Thanks again

https://photos.app.goo.gl/JbSXZH6LmBUnUTqJ9

[zoombini]

Great thanks guys it’s now getting into gear but now when I release the clutch the engine is cutting.

Maybe some more adjustment of some kind is needed?

https://photos.app.goo.gl/m8sweLRQZXwTQcZ46

https://photos.app.goo.gl/m8sweLRQZXwTQcZ46

[zoombini]

Okay so I’ve got it going but it’s driving kinda janky.

I think it’s the adjuster on the gear linkage.


https://photos.app.goo.gl/z7Pjc5sNUR5xQH8DA

Tight makes it kinda jumpy, I have to kind of keep my hand on the clutch otherwise it lurches or stalls. I can change gears but it feels unsafe.

https://photos.app.goo.gl/igfEJRAZPeYtHYb29

If I loosen it the engine cuts when I release the clutch

Maybe it’s something else?

https://photos.app.goo.gl/z7Pjc5sNUR5xQH8DA
https://photos.app.goo.gl/igfEJRAZPeYtHYb29

[rpsmith79]

Was it cutting out before the gear linkage fell off?

There should be a couple of mm of free play in the clutch lever, if you have adjusted it out too much, you may end up riding the clutch, and you will rapidly wear it out
____________________
Current Bike: Honda CG125 ES4 // Honda CB600FS Hornet // Triumph Street Triple R

[stinkwheel]

Sounds like you may have disturbed the sidetand switch too. There is a safety interlock which stops you riding off in gear with the stand down. It cuting out when the clutch is fully released suggests to me that it thinks the stand is down (there's a switch on the clutch lever too which bypasses the safety system when the clutch is pulled in). The neutral switch is also involved in this interlock system.

Is the neutral light coming on?

Clutch switch might also be involved/dodgy.

As a test, you could disconnect the clutch switch and jump between the green on yellow and the yellow on black wires (a bent paperclip will do it) and see if the problem goes away. This effectively makes the bike electrics think the clutch is pulled in all the time. It's not a fix, but it'll tell you if the problem is in that safety cutout system somewhere.
____________________
“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.

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[to v or not to v]

[stinkwheel]