TOPIC:

I bought a 1985 GPZ 550. After cleaning the carbs I was able to start the bike and run it with the clutch engaged. As soon as I let it off the engine dies. It seems to me it's stuck between two gears, but before I take it out to see I thought I would run it by you guys. Thanks,
-Mark

Clutch lever pulled in = clutch disengaged.

Does the bike have a center stand & did you change the oil? I would put it on the center stand, pull in the clutch lever, spin the rear wheel, downshift to 1st gear, then put it in Neutral. The green neutral light should illuminate. Then start it & shift gears to see what it does while still on the center stand. If it sat a while, the clutch plates could be stuck. I would also do a basic clutch adjustment as per the owner's manual or factory service manual & replace the clutch cable if necessary.

The 550 series motors and transmissions are all very tough and reliable generally.

Kawasaki altered the circlip arrangement on the later 550's to prevent selecting two gears at once, but I've never heard of this actually happening.

Maybe lift the back wheel and see if the starter will turn the rear wheel with the clutch out?

Unlike most other bikes, when stationary, you can't go through the gearbox from 1-6, but only get 1st , neutral and maybe 2nd, The idea is so it pops into neutral easily when changing down.

Ok, I will try those ideas. Is there a place to get service manuals for this bike?

Ok, I took the clutch off and the transmission input turns maybe 1/4 of a revolution. If I try to move the shifter it indicates neutral but it still catches on something. If you turn more it breaks free for a second then catches again. I think the engine is going to have to come out.... Do you guys agree?

I don't know about your trans, but my signature has several manuals, and you should grab all of them. Your model will be covered in the supplements, but you will need the base manuals as well.

Any tips for taking the engine out? I think I will pull the carbs and header first....

Mark Ohio 1976 wrote: Any tips for taking the engine out? I think I will pull the carbs and header first....

Some ideas for consideration --

www.kzrider.com/forum/2-engine/511846-ea...of-my-78-1000#511890

Good Fortune!

Had this once, and traced it to the cranckcase breather bolt being replaced for another a few mm too long.

turning the engine over by hand with the clutch plates removed - it is still catching? the primary shaft drives the clutch drum so in neutral it should all rotate freely. what about turning the back wheel or drive sprocket ?

I'd continue with the diagnostics a bit more before taking the motor out.

Tyrell
Thanks for the advise. I will check for something like your finding before I pull it. I will pull the left cover next

Yes still catching with clutch plates removed

Yes still catching with clutch plates removed

catching from the crank or back wheel motion? if you could pull the clutch basket off you could tuern the layshaft and mainshaft independently although I'm not sure what that would reveal .

The primary shaft on these (unlike the z900/1000/1100 series where it is mounted on the side of the crank)
usually fails by slipping on the starter motor. Very unlikely but does the starter motor turn when you move the crank? if so possible primary starter clutch problem..

Take the spark plugs out, turn motor by hand and 'feel' where it is catching somewhere - between the crank, primary chain, primary drive shaft/clutch basket drive gear . If doing this for the rear wheel causes the same I guess both your gear shafts are stuffed. No probs, they are two a penny cheap for 550's.

Drain the oil and drop the sump will let you see some of the gearshafts. If you need to strip the motor leave it in the frame for now - the clutch centre and primary shaft nuts, (which you need to loosen when splitting cranckcases) are very tight and much easier to loosen in-frame.

So I have some new information. When I turn the inner clutch shaft it can be turned clockwise with resistance. It clicks past something. It will not go counter clockwise. I have not accessed the output shaft yet.

The starter works and the engine turns over fine with it....does the starter clutch still need checked?