V650

I wish I removed the clutch and basket again The gearbox is still not engaging after 3rd The selector drum seems to stop halfway round and the pin that the selector engages does not make it down low enough for the lever to push Photo 1 is the selector and you can see that the pin has not rotated enough for the arm to catch Photo 2 is the Cam on the other end of the shift drum and the roller has not quite made it in to gear I drew on it with a marker 1 for 1st gear N for Neutral 2 for second gear the Roller should be in the dip

Start with the basics Set your meter to Volts DC Start the bike up Probe the battery Red to + and Black to - and give the bike a little rev prob about 3000 rpm and see what voltage you are getting You should be seeing about 14- 15V If you are not getting an adequate supply to the battery and you say you have changed rectifier then I would be looking at the stator output But check the volts at the battery with the engine running and about 3000 RPM as a first

Thanks for the reply Trying to set the clutch was being done with the bike on the ground by putting it in gear pulling in the clutch and trying to roll the bike forward and it would not move I tried adjusting via the adjuster at the clutch lever on the handlebars and also the adjuster near the clutch cover and by the time it got to a point where I could roll the bike it was too much and had disengaged the drive to the wheel even with the clutch lever let off I have taken the clutch off again to have another look Cheers J

Been out tinkering with the bike Took it off the paddock stand to try bring it for a run I was checking the adjustment of the clutch by putting it in to first gear pulling in the clutch in and pushing the bike to see if the clutch was releasing and to my surprise it did not The clutch lever and the clutch actuating arm on the clutch cover seem to be operating normally and I had oiled the cable and the cable is about a year old and moves freely and seems to be in good condition I can feel resistance against the spring but it was like it was not doing anything the drive still seemed to be engaged So I started to adjust the clutch more to try get it to the point where the drive to the wheel was disengaged several turns later the back wheel started to turn while pushing in gear but there was no drive to the wheel when in gear & the clutch was released with the engine running In order to get drive to the wheel I had to slacken off the adjustment but then pulling the clutch in while in gear did not appear to to release the drive to the wheel Sorry about the long posts but this is doing my head in Could this be why it wont go in to gear above third and not a gearbox problem at all? Or is that wishful thinking J

Thanks for your reply That is a great Idea and certainly worth a shot as I have just been testing with it on the paddock stand This afternoon I will put the chain back on and take it for a gentle run through the estate and see if anything jumps in to place Thanks for the suggestion J

Hi Ian Thanks for the reply Yeah have the service manual and it seems straight forward this is a cassette type gearbox Manual says to put it in neutral position Slot the gearbox back in and insert the selector and cover check the drive and output shafts rotate freely in neutral Kawasaki use what they call Positive Neutral finder "The transmission is equipped with a positive neutral finder. When the motorcycle is standing still, the transmission cannot be shifted past neutral from 1st gear. To use the positive neutral finder, shift down to 1st gear, then lift up on the shift pedal while standing still. The transmission will shift only into neutral " I am guessing this is working as I am able to shift from 1st to 2nd to third but after that the Lever comes up as usual but nothing happens it does not move in to fourth This is being tested with the bike on the paddock stand Last week with the old gearbox I was able to clean the chain and cycle through all gears to sling the excess oil off the chain before cleaning the rear tyre photo is of the Selector and Neutral switch

Hi All I have a kawasaki versys and the Output shaft was damaged due to the front sprocket nut being too loose Ok So I decided to make a start on replacing the Transmission / Gearbox as the output shaft were worn to a point where I felt that I would put it in gear and the sprocket would just strip off what was left of the metal Photo attached is of the offending article Sourced a replacement box on ebay Have hit a bit of a dead end Gearbox is back in and the chain is on adjusted the clutch cable put in some fresh oil Bike is on the paddock stand Turned the key & neutral light comes on wheel rotates freely Start it up and it did not burst in to flames Engine running and I can select first gear bit of a clunk but it goes in Try second gear and wahoo second works also Try 3rd and its like its back in neutral no drive & the wheel stops rotating Try 4th and it wont go in just makes a bit of a grating noise so I did not want to do any damage so I stopped This morning I tried it again same thing so I thought maybe the shift rod needed a little adjustment and I spent quite a while adjusting it back and forward with no success No Matter what I did it just will not go in to any gear after 2 Thinking the replacement box was duff I took it back out When it was out I noticed that the Locating dowels were still in the old box I had forgotten to swap them over and although I was skeptical that the dowels would make any difference I put the box back in with the dowels Needless to say it made no difference So I took the box out again getting quicker at it now I swapped over the good output shaft in to the old box and reinstalled and the blasted thing is the same with the old box wont go past 3rd gear The old box was working ok other than the shaft damage so I'm thinking it must be me doing something wrong on installation as both boxes are exhibiting the exact same symptoms Any gearbox guru's out there can point me in the right direction ? Or any input at all is welcome at this point I did not dismantle the selector I just removed and reinstalled it while replacing the gearbox Cheers J

Yep as above Replace fluid and bleed Check disc and pads for contamination

Shocking how some of these people manage to get dressed in the morning never mind drive

Went for a jolly in the wicklow mountains about 80km on the V

I have one of these that i bought about a year ago https://www.overlanders.ie/product/motopressor-pocket-pump/ No built in pressure gauge but I have a seperate digital gauge pump is quick small and light

Thanks for that info The C5 looks good but as you said very pricy Cheers J

Use the Oxford Ear Plugs SNR37 myself I have some hearing loss after working 20 years in an engineering company I have a HJC helmet with the bluetooth kit and listen to music from the zumo they do block out a lot of noise but I can still hear the music With no music on i can hear my tinnitus ringing Was thinking of maybe getting the Schuberth C4 as as I had read some reviews that they were one of the quietest helmets

This Sealy one Have used it on 2 chains and seems to work fine for me

Chain and sprockets over the weekend €95 from Carpimoto Got about 20000 km from the last set

Went for a 50k spin during the lunch break cool but bright day here

Passed the test this week at 57 years Went back to bikes after having a Gsx 250 30 years ago but only ever had a provisional licence here in Ireland IBT is 18 hrs but once completed you can go out on the road and lasts 2 years Have put about 20000 Km on the Versys Passed the test in the wind and a bit of snow with 0 faults

Also using the Zumo xt Had tried a phone in a zip waterproof case but sometimes could not see the screen with the glare on the plastic case like the one pictured above Also read some users accounts of vibrations breaking the phone's camera I was using an old Samsung so that was not an issue for me J

My oxford ones take about 5 mins also till you can feel the heat come through the gloves

Or this one

Started when I was 22 on a Suzuki GSX250 56 now and back as a Lerner after 34 years away On a Kawasaki V650

Disappointing also use Wemoto but no such email sent to me

Gave the Bike a blast of ACF50 today after the storm as it stays outside year round have the oxford heated grips and with the big winter gloves I don't find them too hot paid about €60 for the UK spec ones Connected directly to the battery and auto shut off seems to work well

I Like it looks nostalgic and straightforward to work on If it is able to stand up to British and Irish Roads and weather I could see myself cruising round the Wicklow hills on one of these

Happy Christmas & Greetings from Wicklow Ireland