not shifting out of neutral

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12 Dec 2015 18:25 #702893 by carloskunz
not shifting out of neutral was created by carloskunz
I picked up an 81 kz550 last night. Bought it as a Christmas present for my brother. Bought a new battery and spark plugs, and she started with choke on. Unfortunately, I cannot get it to shift out of neutral. What should I do? Any ideas what the problem could be? The shifter moves easily, just doesn't change gears. Stumped.

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12 Dec 2015 18:32 #702894 by SWest
Replied by SWest on topic not shifting out of neutral
Common complaint for newbes. It won't shift into second unless it's moving. (safety feature)
Steve

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12 Dec 2015 18:48 #702896 by 650ed
Replied by 650ed on topic not shifting out of neutral
With the engine running - pull in the clutch and push down on the shift lever. It should go into first gear. Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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12 Dec 2015 18:53 #702898 by carloskunz
Replied by carloskunz on topic not shifting out of neutral
Had the engine running, won't shift. Foot lever feels real loose compared to my 03 shadow spirit 1100

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12 Dec 2015 19:15 #702899 by SWest

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12 Dec 2015 19:16 #702900 by carloskunz
Replied by carloskunz on topic not shifting out of neutral
After putting it up on rear kickstand, I find that to shift I need to push the shifter in towards the crankcase With a fair amount of force before it will engage and then it will shift. The problem is that this is not really feasible while riding. How do I fix it?

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12 Dec 2015 19:17 #702901 by carloskunz
Replied by carloskunz on topic not shifting out of neutral
Possibly. How do I tighten it?

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12 Dec 2015 22:56 #702907 by floivanus
Replied by floivanus on topic not shifting out of neutral
There's a pinch bolt on the rear of the shift lever, if that's tight and there is no slop present between the shifter and the splined shaft the issue could be internal (behind the trans door)

my bikes; 80kz1000(project), 77 gl1000, 74 h2 (project)
Past; 78 kz1000, 83 kz550
Andrew

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12 Dec 2015 23:25 - 13 Dec 2015 00:24 #702909 by martin_csr
Replied by martin_csr on topic not shifting out of neutral
I would do a basic clutch adjustment first & probably replace the cable in case it's stretched or worn.
Note: when doing the adjustment, turn the clutch release adjusting screw counterclockwise first until hard to turn, then clockwise 1/4 turn. some manuals are ambiguous as to which direction to turn it.

Also, maybe change the oil & oil filter, warm it up, get it in first or second gear & take it for a spin over a rough road or RXR tracks if possible, in case the clutch plates are stuck together or something. The problem is probably the shift mechanism, though.

The Kawasaki service manual should have a laundry list of things to check in the troubleshooting section.
Not the 550 manual, but the following site has the 81 KZ650 pdf in the Files section. jarlef z650 . The troubleshooting list is near the end, chapter 8. The 550 is probably similar so the things to check would probably be the same.
Last edit: 13 Dec 2015 00:24 by martin_csr.

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13 Dec 2015 04:04 - 13 Dec 2015 04:04 #702918 by SWest
Replied by SWest on topic not shifting out of neutral
Take the lever off and look at the splines. I've had to widen the pinch gap so it would clamp down on the splines tighter. I use a longer hardened bolt. Longer in case it breaks and you can screw it out.
Steve
Last edit: 13 Dec 2015 04:04 by SWest.

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13 Dec 2015 04:46 #702922 by rrsmsw9999
Replied by rrsmsw9999 on topic not shifting out of neutral
My 81 550 FSM has a misprint on the clutch cable install. There is a small supplement area for the 1981 A2 model clutch adjustment. The mechanism is ball and ramp on the 1981 A2. The book is printed to turn the clutch adjuster bolt clockwise till tight and back off. It took a few pops and clutch cover removals for me to realize the adjustment was fully open and allowing the mech to pull through the ball and ramp. Turned counter clockwise and backed off a bit and things were as they should be. Clutch lever input was nice and smooth with clear disengagement.

1980 KZ 1000E2
Crashed 6/2016

1980 KZ550A
Sold 3/2016

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13 Dec 2015 05:26 #702929 by SWest

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