1st to 2nd gear problem

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miles · #1 Unread post by **miles** » Sat Apr 29, 2006 4:32 am

Hope someone is able to give me some help...first time on this forum.
I have a '94 concours with 46,000 mi , very well taken care of ,and driven more like a touring bike than a sport bike . Recently it began missing or comming out of second gear . Shifts normally into first , but more and more it's either not engaging second ( lift shift lever and nothing there ..after several attempts ' some times it "feels " like I can just reach it ...and that means if it does drop in , it's most likely to pop back out ) or going in without the solid clunk it usually has , and that's a warning it probably won't stay . Outside linkage seems ok , that is to say , when shift lever is raised , shaft rotates all the way to stop . When downshifting , trans works like normal . In fact ,in town I'm downshifting to second and then not using 1st at all , so as to not have to deal with problem in traffic . I've been riding 42 years , dirt and road , never had a transmission problem til now ... would really appreciate any help .....Miles

TechTMW · #2 Unread post by **TechTMW** » Sat Apr 29, 2006 10:02 am

If you are sure that the adjustment on the shifter is proper, then the problem is most likely internal ...

This probably requires the case to be split ...

CORSCO · #3 Unread post by **CORSCO** » Sat Apr 29, 2006 11:56 am

Sounds like 2nd gear shift fork is bent. Looking at about 10 hrs. labour (my place is $64 p/hr) and a grand in parts, on the high side. When dealing with transmissions,I like to replace damaged forks (most of the time, all forks are showing wear and need to be replaced), ALL related gears, shift shaftS, and shift drum. Then all the gaskets and lock washers. Only the bottom end will be torn down if that is any consolation. The thing about transmissions, is you do not want to due the job again, so get everything. Good luck

OMJunk · #4 Unread post by **OMJunk** » Wed May 17, 2006 12:53 pm

Kawasaki has a second gear lockout that can cause problems. I bet 98% of my missed shifts have been to second from first. The first thing I would do is change oil. Frequently this will help by lubing the lockout mechanism. At least it won't hurt or bankrupt you. If major repair is needed, buy a complete engine from Ebay. They are often on ther for $300 to $350. Good luck!

MotoF150 · #5 Unread post by **MotoF150** » Wed May 17, 2006 12:59 pm

change ur oil and use AMSOIL this time, problem solved

CORSCO · #6 Unread post by **CORSCO** » Wed May 17, 2006 3:45 pm

If you need it rebuilt, DO NOT buy an engine from E-Bay! More times that not, you are buying another's problem. I have seen it too often.
One guy bought a CBR600 motor from E-Bay and brought it to the shop because of an oil leak. The alternator cover was cracked. I took it off to "repair" it (customers wishes, I hate making things work...I prefer to do it the correct way). What I found inside was horrible. The starter gear idler shaft had busted the boss on the CRANKCASE as well as punching the hole in the side cover.
Others have bought them because of tranny issues and wind up WITH a motor with tranny issues. It seems like to much of a gamble for me.