I just bought a 2010 klx250s new from a dealer. I rode it on the street a few times, never getting it above 5,000 rpms. Then rode it at an ohv park and was still babying it, everything was good, had about 40 miles on it. Took it out this weekend on some fire roads, and here is what happened.

I locked up the front wheel going down hill at about five mph, and slid onto its side. It bent the shifter into the transmission case. It could have only bent about 1/4 -1/2 inch. Bent it back out...

I was stopped in neutral, went to shift into first and it ended up in second/third? gear. The shifter would click but it wouldn't go into any other gears or neutral. I was able to ride it about twenty yards and then it just revved up.

It seemed like it was stuck in neutral, however no neutral light on dash. The shifter still clicks up two times but no actual shifting?

Obviously something broke inside the transmission with only 50 miles on it.

I guess I am just looking to see if there are any ideas of what happened.

And more importantly if there is any way the dealer is going to say that they wont warranty it.

 

There is a sticky about the shift star, common problem after a get off, read up.

 

I doubt you broke anything inside the transmission but you probably broke one of the pegs (or pins) off of the shift cam. Fortuneately that can be accessed without splitting the cases. Most of the shift mechanism is outside of the engine cases and beneath the small cover on the lower left side of the engine. It's the cover under the shift lever. Read up on it in the manual. It's very easy job to replace the shift cam your self.

 

I took a header last summer just like yours and thought i had a shifter issue,,,it turned out to be a clutch cable issue. When i hit the ground the clutch cable got pulled out enough to fully disengage the clutch.
Check it out and see that you have a working clutch.

 

I too, think you broke a pin on the shift star. Relatively cheap/easy fix.


Is there a way the dealer will say they won't warranty it? Um, yes there is a way they will say that! ......... It didn't break, you broke it. Right?

I have a lot of stuff Kawi would have to warranty if they covered stuff I broke while crashing.
Good luck with the repair. Lots of good info on here.
Dan

 

shift star for sure, done it twice now. with basic hand tools and a little knowledge, it pretty easy, hardest part is removing the shifter in most cases (stock one can be on there pretty tight).

 

The shift star is broken...and as a result it fried the clutch plates.

So now what am I looking at for repairs...

 

If you use the search function you will find out everything you want to know. Plenty about the shift star and clutch replacement. As it happens this has all come up recently.

 

Read up on the threads.

Replace the clutch springs with barnett springs, even stock motors need them big bores for sure....

Shift star replacement is very easy, do it yourself. Save money.....

 

Kawasaki is replacing it all for free.