KZ 400 Shifter Pedal not Returning

TexasKZ wrote: 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.

Thanks. That's what I was figuring based on my online research. I took the left side cover off and even with the clutch disengaged completely the pedal was lose. I found out how to get to the spring Here on page 76. Looks like it's going to be a difficult job getting to the spring.

The link won't work for me, but the spring should be relatively to access.

Tmiron, thanks for asking here and reminding me to thank everyone previous who helped me with their awesome advice! Motorcycle life got so busy that year I completely spaced on coming back around and updating everyone on how amazing and easy a job & fix that was!

I had to get a hammer drill, or impact driver I think it's properly called, (Harbor Fright) with the Japanese Machine Tips as recommended (NOT Phillips head!!!) and the worst screw maybe took 7-10 gentle-but-firm held whacks to come loose. Is yours a KZ1000? It may have allen heads which could be easier to remove? Nonetheless, I don't know how different the two overall designs will end up being, but I can't imagine they'd be THAT different - As you can see from the video I did (and just uploaded tonight to reply to your question ) the spring is



EASY TO SEE & FIX, once you remove the clutch basket and primary chain and all the stuff between those parts and the right case cover lol

That was the 'hardest' part. Really, just getting the circlips off some of the retainer rings on the clutch & timing / drive shaft was a challenge - I didn't have the 'proper tool' but I figured out how to rig a pair of needle noses and a flathead screwdriver 'just so' and they came out with a little nudging and meditation lol ...

Hope you have a great time tearing into it - I know I did, and again, I have to thank everyone here for their wonderful advice and support! Miko

It's under all that? Good to know for the ones with the 400/440's.
Steve

Thank you so much Mikoarts!!! Mine is a KZ400 as well and this video is just what I needed!!

Were did you guys get you JIS bit? I've got a whole new sew of hex head Stainless steel bolts to replace everything with, but having the proper bit to get the old screws out might help.

Thanks again, you are a life saver!

@Tmiron - No problem at all!

You know, the set at Harbor Fr(e)ight came with EXACTLY the bit I needed! Just go get the set - It was just a couple bucks ($8 maybe?) and just sitting around since then probably caused the self-destructing-H-F-Nano-Tech to self destruct, but! Fortunately the sets I think all come with exactly the bits you need - Go down there and grab one! Let's see the pics as you tear in!

Get a hand impact driver. Every tool box needs one.
Steve

Thanks for your help! It was in fact a broken shift pedal return spring. I ordered a new spring, gasket, and oil filter. I have a question about putting it all back together. It seemed like there was a sealant on the the two screws that held the shift shaft in (#5 in the photo below). Liquid gasket? Locktite? Thanks!

Take a look at your Kawasaki Service Manual in the table that shows torque specs. There you will see which fasteners require a locking agent. Ed

They changed the spring. The early Z1's had a two wound spring that was weaker than the later ones where they added another wind. Z1 sent me the weaker one and I had a three wind one so I kept this one as a spare. Not worth the postage there and back plus the little more I had to pay for the better one.
Use some lock tight on those two screws you were asking about.
Steve

Crap, I just ordered one from the Z1 link above. Am I going to get the weak one? Where did you get the 3 wind one?

I apologize for my previous comment. :blush: On the bigger engines, that mechanism is on the left side of the engine and much easier to access.
Sheesh. :blink: