Well the K5 S**t the bed saturday...

[Ims Roll]

So i made it about 1/2 of a mile into my ride satruday, (after losing 2 rear tubes and the alm carrier on the rear shock of my 300) and after a quick stop and turn around (to check my shinny new emig link, thanks guys) it slipped it's self into what seems like neutral    i can feel it upshift/downshift but it wont stay in the gear, just dumps back into a neutral.  Now could this be the dreaded 3rd gear i hear about or (what i'm hoping for) the oh so weak cir clips? any ideas? I need soothing as ive been working on this pig for 2 weeks now every day getting her ready for the season. I have the motor out sitting on the bench with the top end pulled, looks good. I will attempt to split the cases tonight and see what i can find. i should be able to get to the tranny without pulling any major barrings or the crank current? I'm not as familiar with this as i would like to be but it's my buddies bachelor party ride weekend next weekend and i would like to have her back up n running in 5 days, possible?

Thanks guys.

[Foxx4Beaver]

I just went through the same thing...still in the process of putting it back together(just waiting on my jug and head from Todd).Mine was jumping outa gear under full power...3rd,4th,and 5th were all doing it.
With mine, it was a combination of gear dogs/forks/drum being a little worn...sooooo,I took the high road and dropped $1200 on a complete new tranny....but the kick in the nuts over the whole thing, was that when I pulled my jug off to start disassembling the motor, I found out I had a cracked intake bridge ...so off to Pinnsonault the jug/head went, since he's only a little over an hour away from me.
As of right now...I'm about $2400-$2500 into this motor rebuild...with new inner clutch hub/pressure plate/clutch plates and springs,cylinder studs/nuts,gakets..etc,etc....oh yeah,I'm balls deep into this one!

Sorry if this wasn't "soothing"....but, as the old saying goes...."expect the un-expected"! 

[Ims Roll]

oh boy, mines not jumping out of gear though, it's not even going into it. and i feel you i just got done with a $1900bill from this same motor... not but 7 months ago...

[Foxx4Beaver]

oh boy, mines not jumping out of gear though, it's not even going into it. and i feel you i just got done with a $1900bill from this same motor... not but 7 months ago...

haha....yeah but hey, it's only money right?....if I wasn't spending it on bikes, it'd be on my local Escort services and things that make ya feel funny

[kxpegger]

Don't know if Kawasaki is the same as Suzuki but the transmission shaft circlips are directional on the Zook. The circlips have a smooth side and a unfinished sharp edge side. The smooth side faces the gear. If the smooth side faces away from the gear then it can pop out of the shaft groove under load. Don't know if Kawasaki is the same as Suzuki on this issue. When everything is new this may be less likely to happen. Not saying this is your entire issue but something to watch out for.

[Ims Roll]

So just a small update, last night i got to playing around with the ol' girl for a bit and upon pulling the right side cover i found two small pieces, sorry no pics i was excited. the parts looked to be of the spring return on the shift mechanism,

i held it with my figure and had the Mrs. do a little short shifting and everything worked perfect. i'm ordering the spring, will test with the spring and i think it should be ready to role.

Does that spring attach to the small dowel type pin, looks to be part of the case, directly above the lever?

[sandblaster]

[Ims Roll]

thanks sandblaster, it just sits on that pin and wont fall off?

[sandblaster]

The spring is too tight to slip off..

[Ims Roll]

figured i'd ask usually there's a mushroom tip or a grove they sit in. this one is completely smooth, i'm assuming that spring will be a bear to put on? i wont get it till tomorrow .

[sandblaster]

Yep, the shaft is smooth and it's easy to put the spring on..

[Ims Roll]

Thanks buddy, hopefully this is my only problem.