No gear engage

TexasKZ wrote: Has it been a long time since the bike was ridden? Is the oil fresh? What kind of oil?

It is possible that in addition to the adjustment problem, the clutch plates may be stuck together, though one or two sudden lurches like you described should have loosened them.

Second that.
I had to take clutch discs apart once because disks got rusty and stuck. Just few minutes of sanding of metal disks solved the problem. Enjoy taking clutch apart! :woohoo:

If it sits for long they can be stuck together. Sometimes just riding it will free them. I had them apart last year and found one that was cracked. Rather than putting in a old one I had laying around, I put it back in. I buried it in the center. It would grab from time to time. I won a whole basket assy. $40 Came off a low mile KZ 900. Like new. It's a easy job and I'll get to it soon.
Styeve

Bulldogar wrote: thanks man.
I`ll try that this weekend.
regarding your second answer: the problem star one night while I was riding the bike. Was in 4 or 5 gear and then was needed to switch a gear but I felt the clutch very loose, I try to adjust the clutch cable in the middle (where the exhaust begin, while riding) but i couldn't fix it then I pull over aside of the road to check what was going on but no.
I took the bike without clutch to my house (you can hear the hit everytime you switch a gear).
At next day try the common adjustment but didnt work.
The oil was "new" (10w-40, Valvoline) a month and a half at the most since I rebuild the bike and that night was one of the first rides that I took.

From what you're saying above, this isn't a sitting issue or anything like that, the cable, or clutch actuator had some type of fault (loose feeling clutch) that keeps you from properly using the clutch (declutching) I would start with pulling the sprocket cover that holds the adjuster and go from there. Make sure it is lubed, in one piece, and functioning. Also with the cover off PULL in the clutch lever and verify the cable isn't broken. Cables seem to break often on these bikes, corrosion and build up contribute to the problem

I have a PDF copy of the factory service manual. I can email it, but because it is such a big file I'll have to use Dropbox to send it. If you are interested, pm me your email address.

I have a dropbox account as well. will really appreciate that file.
arturoha_87@hotmail.com

maybe this is gonna sound very hilarious but I cant remove the disc clutch cover, bolts are stuck.
It's a damn headache.

Which cover?









Which screws?



Good Fortune!

If the screws are stuck, try soaking them for a couple of days with Kroil or some other good penetrant. A hand impact driver is also a great help. If the cross-head screws are still present on the sprocket cover, be sure to use a JIS bit or a suitably modified Phillips bit.

Wow, thanks man.
The clutch cover and the screws are Allen.
The oil leak that I mentioned is from the alternator cover and it goes from there to the sprocket cover.
You know, the problem with the screws is that they are very old and rusty, I tried to remove them but the head draws are a little damaged.
I`ll try to fix it right now.
!Thanks for the manuals file!

.

You can buy a new grommet for the alternator. It takes cutting the wires and soldering them. If you decide to do it, start a thread so we can guide you along.
Steve

Bulldogar wrote: . . . You know, the problem with the screws is that they are very old and rusty, I tried to remove them but the head draws are a little damaged. . . .

It sometimes helps to heat a screw head with a propane torch and get it good and hot just before attempting to remove it.

Heat expands the aluminum female threads more than it expands the steel male screw threads, which tends to release the thread grip.

Heat also relaxes the grip of any red loctite that might have been ill-advisedly applied to the threads when last assembled.

Before using the heat method, would first soak for a few days with penetrant as suggested by TexasKZ.

And be careful to avoid further damaging the screw heads.

Good Fortune!