KLE500 wont engage gears after falling over

[stinkwheel]

KLE just fell off its stand onto the left side. Now I have no neutral light (in neutral) and it wont engage any gears except first which is stiff as hell.

It bent the lever a little (not much) and nothing is impeding the movement of the lever.

I am thinking bent selector shaft buyt anything obvious I am missing?

If I can't fix it in the next hour or so I'll have to take the GPZ
____________________
“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.

[stinkwheel]

Right I'm off to strip the external gearshift mechanism.

Wish me luck!
____________________
“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.

[veeeffarr]

Something's not right here... Stinkwheel asking for help?

Hope it's not too bad fella.

[BFG]

Damn bad luck! No ideas on the gear selector, but just a sanity check on a real long shot - you haven't clobbered the clutch lever too?

[ZRX61]

Kaw's have a device to only allow you to select 1st or neutral unless the bike is moving....

[phantomtek]

[0ddball]

From previous posts i'm pretty sure he's already aware of it.

[stinkwheel]

Right. Just got back from my run. Landed up taking the GPZ.

It looks like the gear selector has been over-rotated as the bike hit the ground. The keyed drum on the external selector mechanism is out of position so the little roller is sitting between two grooves. It also won't move more than a couple of mm in either direction.

I suspect either one of the pins has bent or possibly a fork has jumped out of its groove in the selector drum.

Boils down to, engine out job. If the engine is coming out, my spare GPZ500 one is going in.

Looks like my Easter long weekend is being spent in the garage then.
____________________
“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.

[stinkwheel]

I don't suppose anybody would be willing to scan the ignition circuit diagram for a GPZ500S D1 for me? Really just the bit with the IC igniter, pulse and ignition coils (I think there is a seperate diagram in the manual somewhere).

I will need to alter the KLE wiring to take the GPZ igniter and my GPZ manual only covers the A, B and C models.
____________________
“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.

[phantomtek]

I have a Haynes for the GPZ/ER5 if it's any help? There is a wiring diagram for a EX500D?

Unfortunately can't scan it through but if you need help what goes where I'll help the best I can.

[stinkwheel]

[phantomtek]

Right I'm totally useless, managed to dig some batteries out and take some rather shitty pictures of the diagram for you, not too sure what you want me to do so I've taken a picture of what the IC Igniter looks like and the wires etc. They aren't the best pictures I know but it's the best I can do till I get access to a scanner on Wednesday, or maybe tomorrow if these don't help. If you need more detailed explanation I'm happy to help, more, sorry again for the shit effort

https://www.bikechatforums.com/files/dscf0023_190.jpg

https://www.bikechatforums.com/files/dscf0019_356.jpg

[stinkwheel]

Thanks a lot for that.

I appreciate you taking the time to do that for me.

Not surprised you don't understand it, the circuit is fiendishly and unecessarily complicated. Going to take me a couple of hours to puzzle out what is happening there but I have the wires, their order and their destinations there.

Three of those wires are part of the system that stops you riding off with the stand down and such. It is a horrible logic circuit inside the fuse box which thankfully my KLE doesn't have. I just need to work out if I actually need to connect those to anything, I suspect one of them will need to be fed a 'dummy' current to convince it the clutch is pulled in or something.
____________________
“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.

[phantomtek]

[stinkwheel]

Ok, just one of them I can't figure out. Can't quite make out the writing for what the componant is that the white on green wire connects to. I marked it on the picture.

Thanks once again.
____________________
“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.

[stinkwheel]

[phantomtek]

It's the tachometer, a few more close up pictures:

https://www.bikechatforums.com/files/dscf0049.jpg

https://www.bikechatforums.com/files/dscf0053_116.jpg