KZ 400 Shifter Pedal not Returning

Thanks in advance! -

I'm helping a friend repair their kz400 - The problem is with the shifter-pedal. It no longer does that much under-appreciated 'return to center' springy-thing easily taken-for-granted except for when… it stops working!

It goes into all gears, IF I have it up on the center-stand and shift it by hand up/down - But, the pedal will not actually return on its own. It has to be maneuvered by hand, or with foot (if while driving). It's been a little bit of a challenge to locate much info on this as 'clutch pedal spring' etc all return ambiguous/unrelated google results -

Do you have any idea what might cause this / how difficult a fix this will be?

I would say part # 6 - gear change peddle return spring.

www.cmsnl.com/kawasaki-1977-kz400-a1_mod...t/51427.html#results

can also be caused by years of dried out, built up chain goo.

If you determine the spring needs to be replaced you will find it is no longer available from the dealer; it is listed as "Canceled" on Kawasaki.com (see diagram below). However, the parts reseller at the following link has 4 of them in New Old Stock for $5.51 each. Ed
www.themotorcyclepartsoutlet.com/cgi-bin/store/index.cgi

No expert here, but when I was replacing my 650's clutch cable, I had a similar problem...I had to fiddle with the final alignment of the engine side cover so that the shifter shaft didn't bind in it's seal.
I think they made a pilot tool specifically for that..

Found a spring for you.

www.z1enterprises.com/ItemDetails.aspx?i...KZ400&item=PM81-3171

Thanks to all you guys - It's been super cold here in Albuquerque the last few days so I'm hoping to get into the right-side of the engine within a few more days… The first problem I'm recognizing is getting past the f@#(*) phillips-screws holding on the case… I'm thinking about using a small butane torch to heat the case (around the bolts) and a hammer-driver to tap the screws out … (Man, the last time I did this, it resulted in a broken carb-boot bolt on the head of my KZ1000 ST … fortunately, these are all 'easy-to-reach' lol) …

The first thing I'm going to do is remove the left-side cover and examine all the parts & crannies surrounding the rod itself, although I doubt anything's encumbering its motion (I don't feel anything at all when lifting/lowering the shift-pedal by hand) .. So, I'm thinking it's probably that spring. (thank you 4TheKZ1000 ) …

Upon close inspection, I don't see a gasket for the right side of the engine. There (is) a gasket there, correct? Worst-case scenario I was thinking I would get some gasket material from ScrotoZone etc & cut one to match - .. Other than the gasket - Does anyone know if I'll have to pull the clutch out to access this spring? I've never torn this deep into an engine and am trying to plan-ahead for how deep I'll have to go (the bike's not at my place, so organization is key to making this a smooth operation).

Again, thank you all - Very much.

This is a purpose tool for removing the screws.

www.z1enterprises.com/ItemDetails.aspx?i...bits&item=EM84-03800
www.harborfreight.com/impact-screwdriver...with-case-37530.html

I have a dewalt drill that has a hammer action, it removes these screws ASAP.....really nice to have one.

You can borrow tools from your local AutoZone parts store. They lend out tools, worth checking into. Might have this tool.

mikoarts wrote: Thanks to all you guys - It's been super cold here in Albuquerque the last few days so I'm hoping to get into the right-side of the engine within a few more days… The first problem I'm recognizing is getting past the f@#(*) phillips-screws holding on the case… I'm thinking about using a small butane torch to heat the case (around the bolts) and a hammer-driver to tap the screws out … (Man, the last time I did this, it resulted in a broken carb-boot bolt on the head of my KZ1000 ST … fortunately, these are all 'easy-to-reach' lol) …

The first thing I'm going to do is remove the left-side cover and examine all the parts & crannies surrounding the rod itself, although I doubt anything's encumbering its motion (I don't feel anything at all when lifting/lowering the shift-pedal by hand) .. So, I'm thinking it's probably that spring. (thank you 4TheKZ1000 ) …

Upon close inspection, I don't see a gasket for the right side of the engine. There (is) a gasket there, correct? Worst-case scenario I was thinking I would get some gasket material from ScrotoZone etc & cut one to match - .. Other than the gasket - Does anyone know if I'll have to pull the clutch out to access this spring? I've never torn this deep into an engine and am trying to plan-ahead for how deep I'll have to go (the bike's not at my place, so organization is key to making this a smooth operation).

Again, thank you all - Very much.

There are NO Phillips screws on any KZ, so if you are trying to remove the cross head screws with a Phillips screwdriver that's one big reason your are frustrated. The cross head screws on KZ bikes are Japanese Industrial Standard (JIS), not Phillips. I know they look the same, but they are not. Take a look at the first link below - it will help. Also, do yourself a big favor and buy a can of Kroil. Soak any stubborn screws with it for 2 or 3 days and you will be amazed at how much easier they are to remove. You can find it online or at some gun shops or gun shows. The second link shows where to get it online. I bought the one on the order form marked "Kroil 1/2 pint (8 oz.) can - $9.25 ea." and it works great . That one can will last me a lifetime. I went through the same fastener problems you are experiencing, but using Kroil and JIS screwdriver tips eliminated the problems.

kzrider.com/forum/21-tools/532335-budget...ewdriver-tips#532335

www.kanolabs.com/

Good (Phillips) point Ed.........

Ed is right, not an American #2 PHILLIPS BIT.

Any word @mikoarts @4theKZ1000 ? I know this is an old thread, but my Shifter pedal is not returning either. Looks like a pain to change the "gear change peddle return spring". Was that the problem on your bike? Any recommendations?

Most of the time it is a broken or worn out spring. They are usually not that hard to replace. This problem can also be caused by a heavy build up of chain lube and dirt where the shifter shaft goes through the case.