Kawasaki KZ440 shift problem

Discussion in 'Motorbike Technical Discussion' started by h_and_p, May 11, 2004.

  1. h_and_p

    h_and_p Guest

    Thanks in advance for any responses to my naive questions -

    Funny (read: crappy) thing happened this weekend: my wife very gently
    layed down her KZ440 in a parking lot. I think she grabbed the brake
    when it was in gear during a slow u-turn and killed it in the process.
    Not sure exactly. Anyway, after that it was tough to shift into
    second, and would usually pop back out into neutral after a second or
    so. On the way home it got worse, and now it practically won't go
    into second at all.

    Now two questions: First, what do you think is wrong? Could it be
    something simple to fix? Probably not?

    Second: I got this bike because it is supposed to be easy to work on.
    Can a motivated person (me) with limited mechanical experience and a
    manual fix it?

    Any help is appreciated.
    h_and_p, May 11, 2004
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  2. Bent lever or pivot fouling on the casing?
    The Older Gentleman, May 11, 2004
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  3. h_and_p

    h_and_p Guest

    I have a feeling that this is what happened. When the bike was layed
    down, I think that the gear selector pedal took much of the weight,
    and may have bent the shaft. I'm waiting for a Clymer book to come in
    the mail, because my Haynes book doesn't make it clear to me what all
    I have to remove to get at this stuff.

    It does say "if gear selection problems are experienced ... check the
    following points having removed the clutch to gain access to the
    relevant parts." But they don't say how much engine you have to
    remove to take out the clutch.

    Hopefully that book gets here soon, and has all the answers ;)

    Thanks for the suggestion!
    h_and_p, May 12, 2004
  4. Bent *gear* lever.
    The Older Gentleman, May 12, 2004
  5. h_and_p

    h_and_p Guest

    All right, the solution turned out to be the cheapest, easiest, and
    dumbest (most dumbestest, for lurking grammar nazis) possible.

    It was just the gear selector pedal that was bent. It was bent
    towards the bike, so it was running into the "bump" on the engine
    casing, but I didn't figure it out right away because when I was
    testing the range of motion of the pedal by hand, it seemed to stop
    maybe half a centimeter before it got to the "bump". But I think that
    was because the bike was stopped, and so the neutral finder wouldn't
    let it go further. I'm not sure, just guessing. Anyway, after
    bending it back out where it should go (by hand -- that's some quality
    steel there) I was good to go. Phew!

    I'm glad I waited long enough for common sense to kick in before I
    started tearing up the bike.

    Thanks again for all your helpful suggestions.
    h_and_p, May 13, 2004
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