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Old 06-16-2013, 08:40 AM   #30
Chopper Rider
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Joined: Jan 2005
Location: On a set of 50,000 mile tires.
Oddometer: 15,038
Originally Posted by Distantrider View Post
  • I have a 2011 KLR 650 that locks up almost every time when down shifting from 5th to 4th. You have to be very aggressive on the downshift and if your real lucky it may go into 4th. Most of the time it hangs up so you have to upshift back into 5th then really shove it back down. I've replaced the clutch pack and clutch cable so far. I ordered new shift rod, pawl, spring clip and shift rod spring. They will be here Monday. If these don't fix it then I'm getting rid of it. I've put 1000 miles on it since I bought it. It's been down more than it's been on the road.

That won't fix it, you have a bent shift fork on the drum, split the cases to fix it. The only way a shift fork gets bent is by the operator. May as well sell it now.
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