Just ordered my shift star last night from FSW... Went for a ride yesterday and had SEVERAL bad shifts.
From 3 to 4 and from 4 to 5, I had at least four or five false neutrals just yesterday.

Also, experienced several times when the bike goes into neutral, but then WILL NOT shift into first gear...
I have to STOMP on the shifter and mess around with the clutch lever (in and out).

That was my first ride after the dealer did the 1st maintenance... What a bunch of morons. Never again.
I've gotta get that crap oil out of my bike and undo the "carb adjustments" that they've done.
The thing runs like crap since I got it back from them. They told me it would have more power and now it has less.
Aaarrgh!

 

Let us know how the modified star gear works out, Kawi. I had never heard of that modifcation before, but looking at the photos over on planetklx, it sure does look like it will make a pretty big difference:

http://www.planetklx.com/techtips/shift-fix.shtml

I personally have had only a few false neutrals and I've always attributed those to my own poor shifting, not quite engaging the gear shift enough. But if the new parts are only $25, it might not be a bad thing to do anyway.

BTW, did you order it on-line or over the phone? If on-line, can you post a URL?

Keep us posted.

 

I ordered online... Go to http://www.fourstrokeworks.com/ and then click on Product Catalogue and then Motors, Engine, Maintenance.

They actually have quite a few trick parts for the KLX 300 that will fit our bikes.
I also ordered the magnetic drain plug and the front brake line guard.

 

On both of my current bikes, I get the same thing, in same situations you describe. It seems I remember that pretty much all the many bikes I've owned in the last few years have done the same thing. It's just the design of most MC gearbox and shift mechanisms. In normal stopping, always first go down only one or two gears at a time, release clutch, then go down to nuetral or first after that -- if that cause trouble too, then downshift one gear at a time, with a brief clutch release between each gear -- that works for sure. I know you probably already know this, but I typed it in case it might help someone that is maybe a relatively new rider, and is still "fighting" their gearbox, sorta. This shpuld smooth things out for them.

 

Admittedly, the false neutrals are happening because of a goofy shift (more because of the rider, not necessarily the bike)...
However, I see it as a short-coming in the design/engineering. I don't think the bike should require me to shift in a particular way to make it happy.

Either I pulled the shift lever up high enough - or I didn't. Change gears - or don't. Don't fall somewhere in the middle.
If this shift star mod works, then I can only blame Kawasaki for not fixing their shift stars sooner.
This is essentially a 10 year old motor so they've had plenty of time to learn and tweak the design.

As far as the not going into first issue... I rarely do multiple downshifts without engaging the clutch. Slowing down, I usually downshift into each gear - I might skip the clutch engagement on second gear when approaching a light. So from 3rd, when I slow down I'll do two clicks to go 2nd, 1st. I almost always find neutral from 1st, not from 2nd. Sometimes I find neutral "accidentally" (going down), and sometimes that's when it won't go into first.

To be honest I can't remember the exact particulars from when the problem happens, but I do know my habits, and slamming down 4 or 5 gears without clutching is definitely not one of them. (Not trying to get defensive, just that I don't think it's my shifting style causing it).

 

Ouch, I guess that's a bit more than $25. Someone needs to fix the description on planetklx - they said for $25. Still, its less than $100 so I guess its worth it especially if it is fixing a problem you are having. I reckon I'll hold off until and if I notice it as more of an issue on my bike. So far mine has not seemed to do this much and on the occasions I have had trouble, it's been more my fault than a mechanical problem.

 

The gear box is definitely not as smooth as a Honda. I am not bashing this great little bike I have had a lot of Honda's and their tranny are smooth as silk. Of all the years I have owned bikes I have missed the most shifts on the klx but I have not missed as many shifts as some are describing here. I never had the bike pop out of gear either. The shift I miss most is from first to second but I blame myself most of the time as I probably did not shift properly. I do notice that it takes some feathering of the clutch to down shift sometimes. I have had every brand of 2 strokes and I never had to feather the clutch to down shift. As long as the bike were rolling, down shifting was never a problem.
This is the first 4 stroke I ever had owned so I thought this might be a 4 stroke thing. Next oil change I will put in some slippery oil and see what happens!

 

I thought my KLX shifted great! never missed a shift. But then again, my last bike was a Buell...so I've learned how to shift an uncooperative tranny! Compared to the Buell, the KLX is pretty slick-shifting!
doc

 

Yes, I've ridden several harleys and buells (the wife works for them).
They are nasty, notchy, clunky transmissions compared to any japanese bike, that's for sure!
After getting off a harley, then riding a jap bike the first few times I shift I find myself stomping on the shifter out of habit.

 

i use synthetic and it seems to help shifting.