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hello guys i have another question my klf 220 jumps straight into reverse without turning the leaver this concerns me because i dont want to knock it down into revers when going at a decent speed any advice  why this is doing this and how i can fix it ?

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Have you unhooked the reverse cable and see if it still drops to reverse?  I'm pretty sure the most likely culprit of your situation is a cable that is too tight, cable is bound, or reverse switch is sticky and not releasing fully.  I'd disconnect the cable and if that resolves it work through the cable and then the switch.  Is the reverse switch a twist knob on the left side like the later KLF220?

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Then the problem is likely in the shift drum. There is a spring and shaft in there and likely the spring broke. Here is a better explanation from a Kawasaki forum I found a while back. 

"If you take a look at the parts diagrams on Kawasaki's web site, look for the gear change mechanism picture to get an idea of how the reverse system relies on the gear change drum assembly to lock in neutral before shifting into reverse.

Then take a look at the picture for the gear change drum and shift forks. Look for the total assembly that is named drum-assembly-change. On the inside end of that unit is the neutral lock named "holder-neutral switch."

Between the holder-neutral switch, and the drum itself is a roller, a spring and a pin. One or all of those have failed, or the holder-neutral switch has broken.

The fix is relatively straightforward, and I would recommend you pick up the repair manual from http://www.kawasakimotorcycle.org/forum/beartooth-kawasaki/, open the unit and identify what is broken, then make the repair.

There is a downside to running with the holder-neutral switch not functioning other that it is dangerous, and that is if the broken roller, spring, or pin drop out they can lodge in the gears and that generally brings the machine to a screeching halt and snaps the transmission case that holds the mainshaft - kind of expensive."

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9 hours ago, D3monic6 said:

I have the book for this bike if you need pix I can scan and send

It’s already available in our downloads, if you have a different version please upload it to the downloads section where we maintain a library of sorts. thanks!



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