KLR 650 gearbox - HELP!
 

I can't shift gears! The lever moves but does nothing. Clutch fine, currently stuck in 3rd so the bike is still mobile, even if the starter and the clutch are getting hammered.

Has anyone seen this before, and can give me hints before I take it apart?

KLR gearbox
 

Hello There.

Has the bike got enough oil in?

Regards

I have no idea but you should ask the question on
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No problem with oil

Sounds like the small spring on the selector quadrant fork has broken.This keeps the quadrant(which is part of the gear selector shaft)in contact with the selector drum.On a lot of bikes you can get to this without really major strip-down,though i can't remember if this is so on the KLR.You'll need to remove the clutch cover,clutch unit complete and it should be behind that.If you're out on the road and can't get the correct spring,a good source is to find an old scrapper car and rob one of the small,light throttle return springs.
If however the selector quadrant isn't behind the clutch,then i'm affraid you'll need to split the engine casings.
Jon.

gearbox
 

dont worry , you will not need to split the engine. if you take out the clutch? you can remove the gearselector .

The clutch will have to come out. Besides that it's a minor operation.