No gear engage

  • car5car
  • car5car's Avatar
  • Offline
  • Banned
  • Banned
    Registered
  • Posts: 534
  • Thanks: 20

Re: No gear engage

13 Nov 2015 14:34
#698529
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:
96 Yamaha Royal Star
82 Yamaha Virago 920

Please Log in or Create an account to join the conversation.

  • SWest
  • SWest's Avatar
  • Offline
  • Sustaining Member
  • Sustaining Member
    Registered
  • 10 22 2014
  • Posts: 23779
  • Thanks: 3045

Re: No gear engage

13 Nov 2015 15:38 - 13 Nov 2015 15:40
#698536
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
Z1b1000 1975 Z1b
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229
Last edit: 13 Nov 2015 15:40 by SWest.

Please Log in or Create an account to join the conversation.

  • floivanus
  • floivanus's Avatar
  • Offline
  • User
  • User
    Registered
  • Posts: 1054
  • Thanks: 116

Re: No gear engage

13 Nov 2015 16:19
#698548
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
my bikes; 80kz1000(project), 77 gl1000, 74 h2 (project)
Past; 78 kz1000, 83 kz550
Andrew

Please Log in or Create an account to join the conversation.

  • TexasKZ
  • TexasKZ's Avatar
  • Offline
  • Platinum Member
  • Platinum Member
    Registered
  • Posts: 8405
  • Thanks: 2789

Re: No gear engage

13 Nov 2015 19:48
#698567
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.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD slowly moving toward resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/forum/11-projects/620336...amateur-build-thread

Please Log in or Create an account to join the conversation.

  • Bulldogar
  • Bulldogar's Avatar Topic Author
  • Offline
  • User
  • User
    Registered
  • Posts: 7
  • Thanks: 0

Re: No gear engage

13 Nov 2015 19:58
#698569
I have a dropbox account as well. will really appreciate that file.
arturoha_87@hotmail.com

Please Log in or Create an account to join the conversation.

  • Bulldogar
  • Bulldogar's Avatar Topic Author
  • Offline
  • User
  • User
    Registered
  • Posts: 7
  • Thanks: 0

Re: No gear engage

13 Nov 2015 20:14
#698572
maybe this is gonna sound very hilarious but I cant remove the disc clutch cover, bolts are stuck.
It's a damn headache.

Please Log in or Create an account to join the conversation.

  • Patton
  • Patton's Avatar
  • Offline
  • KZr Legend
  • KZr Legend
    Registered
  • Posts: 18564
  • Thanks: 2103

Re: No gear engage

13 Nov 2015 23:00 - 13 Nov 2015 23:01
#698579
Which cover?









Which screws?



Good Fortune! :)
1973 Z1
KZ900 LTD
Last edit: 13 Nov 2015 23:01 by Patton.

Please Log in or Create an account to join the conversation.

  • TexasKZ
  • TexasKZ's Avatar
  • Offline
  • Platinum Member
  • Platinum Member
    Registered
  • Posts: 8405
  • Thanks: 2789

Re: No gear engage

14 Nov 2015 05:35
#698605
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.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD slowly moving toward resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/forum/11-projects/620336...amateur-build-thread

Please Log in or Create an account to join the conversation.

  • Bulldogar
  • Bulldogar's Avatar Topic Author
  • Offline
  • User
  • User
    Registered
  • Posts: 7
  • Thanks: 0

Re: No gear engage

14 Nov 2015 10:56
#698630
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!

Please Log in or Create an account to join the conversation.

  • 650ed
  • 650ed's Avatar
  • Offline
  • User
  • User
    Registered
  • Posts: 15334
  • Thanks: 2832

Re: No gear engage

14 Nov 2015 11:14 - 14 Nov 2015 11:14
#698632
.
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Last edit: 14 Nov 2015 11:14 by 650ed.

Please Log in or Create an account to join the conversation.

  • SWest
  • SWest's Avatar
  • Offline
  • Sustaining Member
  • Sustaining Member
    Registered
  • 10 22 2014
  • Posts: 23779
  • Thanks: 3045

Re: No gear engage

14 Nov 2015 11:17
#698633
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
Z1b1000 1975 Z1b
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229

Please Log in or Create an account to join the conversation.

  • Patton
  • Patton's Avatar
  • Offline
  • KZr Legend
  • KZr Legend
    Registered
  • Posts: 18564
  • Thanks: 2103

Re: No gear engage

14 Nov 2015 17:58 - 14 Nov 2015 17:59
#698692
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! :)
1973 Z1
KZ900 LTD
Last edit: 14 Nov 2015 17:59 by Patton.

Please Log in or Create an account to join the conversation.

Moderators: Street Fighter LTD
Powered by Kunena Forum