Shift rod problem !

New member I have a1977 kz 650b that I got as a bracket case my problem is the shift rod my have been pulled out and put in manual says that would require the engine to be torn down to reposition the internal shift forks that's above my pay grade is there an easier way to get this done thanks for your help

You may be able to drop the pan and take off the sprocket cover and shift linkage cover. With the bike on it's side you might slide the rod through one fork then the other. A telescopic magnet can help hold one in place while you work the rod through.
Steve

Steve is right, but there is only about a 2% chance that you will get all three forks back on the rod and positioned correctly on the shift drum. The middle one will be the biotch!! I don't know what kinds of tools you would need to get a hold on that middle one. :evil: My guess is at a minimum to try it u need to get to tranny case, oil pan, oil pump and secondary shaft removal if you try it from the bottom. Maybe more. I have videos of 550 engine teardown and rebuild on my youtube channel. Ron Schmidt

If you end up splitting case, check seals on the crank for good measure. It is not a terribly hard job, but will cost ya gaskets, seals,parts and time.

R

If it's just the two small forks, it should be a simple job. At least worth a try.
Steve

You can see the small shaft and small forks. The shifting drum is in the center. It has a bolt on pin that follows the groove on the drum. It has a bend over keeper for the bolt. It is impossible to remove it without taking the bolt out first.
Steve

Ah yes, two not three. You are right that a try won't hurt. R

Looks like the oil pump is in the way. Do you have a pic with it removed? Pretty damn tight.
Steve

There is some footage in that 20 min academy award picture. :sick:

The shift rod is in the lower case and if the forks came off completely it will be a problem to align them with the shift drum. I looked at the manual and it looks difficult at best without splitting. When it is split they just hang when reassembling. There will be tight quarters and if they completely fell off I don't even know if they would be in the pan or laying in the tranny or under the secondary shaft. Interesting problem. And last the manual does say,do not remove shift rod more than 50mm or else a fork will come off and the cases will need to be split. I don't think it can be done with the drum and gears installed and going through the pan, but it's worth a try if he doesn't want to split cases. I could be wrong,R

It appears it would be possible to put the shifter in neutral Then fish the outside small fork onto the shaft then the inside with a telescopic magnet. I'd inspect the shifting dogs while I was in there. The manual does say not to pull out the shaft but one would only know if it was on hand.
Steve

Hopefully he will try and let us know. This would be good info for 550 owners. I am certain he is not the only or first one to have this issue. :lol: R

I did it once on my Z1 years ago. You could hear me cursing miles away. It's like to old pull my finger joke. :woohoo:
Steve

When I first got my bike in Nov 1980 I brought it in the house and if I remember right took the sprocket cover off to maybe grease the clutch lever....... that rod looked like it needed cleaning and I grabbed on to it and yanked it out .... wiped it off greased it lightly and put it back in.... I then decided to get the manual out to see how you take the clutch lever apart .... when I read the part about "not" pulling the rod out it was maybe the sickest feeling I ever got :sick: :sick: ..... all winter (and I mean every day) I worried and to this day I still get a sick feeling when I think about it or see the high lighted part of it in the manual.

I don't want to get your hopes up and then crash em down but mine was ok..... the only thing I can think of what happened was the dogs were jammed just right maybe to where they stayed in ?? While I was doing the starter clutch repair I taped it in place to make sure it didn't move and yes got a un easy feeling every time I looked at it and while putting the ball and pusher in from the other side. Did you hear one drop ? Maybe you can try it to see if it stayed long shot I know but I swear I'm hoping for you.

I have almost started a thread (a bunch of times) on this asking if this is the case and the rod they are talking about just to ease my mind but didn't want to admit to doing it. :blush: