KZ200 shifter not working

Hi everyone,

Just as I was getting excited that my bike was finally running well, it's gotten stuck in 2nd gear. The shifter pedal isn't catching anything. It moves up and down to the extreme limits of its range with little friction and whether or not the clutch is engaged. The pinch bolt attaching it to the shaft is tightened fully. Any ideas? I'm nervous that it is something major and that I'll have to dive into the engine, something I've never done before.

Any help is appreciated.

Ross

When you move the shift lever, can you see the end of the shaft moving with it?

Could be a broken return spring. It is reference number 23 in the diagram.

www.partzilla.com/catalog/kawasaki/motor...ear-change-mechanism

It could also be the mechanism is fouled up with dried and semi-dried chain lube and dirt.

I would remove the shift lever and the sprocket cover and clean everything in there really well and see what’s up.

Keep in mind that the Kawasaki Neutral Finder will prevent you from choosing any gears other than first and neutral while the motorcycle is stationary.


 

Yes, the shaft moves with the lever. 

I will check behind the sprocket cover and clean it this weekend when I get some time. Thanks!

I finally got around to checking this. After taking off the right side engine cover, I found that the spring that you mentioned is not broken and still works. The shift pedal snaps back to the center if you move it up or down, but it will not change gears. The clutch is still working because I have to pull it to move the bike. Any further ideas?

Thanks,
Ross

After digging more into the whole shifting mechanism, I found the problem. Referencing the diagram linked above, a piece broke off of the shifting shaft (part 24), and that piece holds the C-shaped lever (part 25) in place. That's why I couldn't shift. Found a replacement shaft on Ebay.

Glad it is a simple fix.

Thanks for letting us know.