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TOPIC: Search didn't work. . .neither does kickstarter

Search didn't work. . .neither does kickstarter 3 years 1 month ago #462913

The kickstarter lever didn't come back up on my KZ540.

The electric starter worked for a change and I got the bike started.

Then the kickstarter lever jumped back up and started to make a pawl noise.

So I parked the bike on the side stand and get the clutch cover off.

Now what?
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #462974

  • Old Man Rock
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KZ540...? :huh:
Exact year & model and I'm sure you'll receive an answer.... ;)

Search File base for KZ400/440 Service Manual: ( I just uploaded so may take awhile... ;))

EDIT: Error uploading - Size exceeds maximum permitted. Patton, what's the MAX limit on file submittals?

KZ550 Service Manual:
KZ550 Manual
1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
Keihin, 29mm CR specials
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az
Last Edit: 3 years 1 month ago by Old Man Rock.
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #462984

Thanks for the reply. . .I put the wrong information into my post.

It's a KZ650 1978.

The spring looks ok . . .it isn't broken. . . but a little bit of the plastic sleeve is.

So is that is what caused my kickstarter lever to go limp dic on me?

What secures the case side of the spring?
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463022

Not even a hoody doo from my "brothers' in crime in owning one of these iron maidens?

I think it's the plastic sleeve. I ordered a clutch pack too.

Ho Hum.

And a gasket.

And the sleeve wasn't available from BikeBandit.

But I found one.

So I M stranded for a week.

What do you want to talk about?

The lines are open.
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463100

  • Old Man Rock
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OEM KZ650 Manual... FREE!!!!

KZ-650 Manual...
1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
Keihin, 29mm CR specials
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463104

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Old Man Rock wrote:
...Search File base for KZ400/440 Service Manual: ( I just uploaded so may take awhile... ;))
EDIT: Error uploading - Size exceeds maximum permitted. Patton, what's the MAX limit on file submittals?....

Am unaware of any file size limitation, but notice the 29.08mb Z1-900 Kaw service manual
www.kzrider.com/filebase/doc_download/43...asaki-service-manual
which am guessing is perhaps larger than a KZ400/450 manual.

Will try to get a better answer.

Good Fortune! :cheer:
Last Edit: 3 years 1 month ago by Patton.
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463107

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Not at all for the pdf KZ-440 Manual I have is a whopping 62 Megs... :blink:

AH well, I'll see if I can find some application that can shrink it/zip more then rar extensions...
1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
Keihin, 29mm CR specials
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463109

  • Nelson
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stranded for a week? you can push start it can't you?
I guess listing bikes I have owned is what we do:
78 KZ1000, 01 KTM 300EXC, 01 ZR-7S, 03 Suzuki SV1000, 95 KDX200, 87 KX500, 87 KDX200, 85 XR350, 85 WR400 Husky, 85 WRX400 Husky, 82 KZ750, 83 XR350, 81 GPZ550, 78 XL350, 82 XR200, 78 YZ125, And more... Former Motorcycle Mechanic (eons ago)
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463127

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KaZooCruiser wrote:
Thanks for the reply. . .I put the wrong information into my post.

What secures the case side of the spring?




One end of the spring goes into a hole in the side of the lower case (top pic).

The other end of the spring goes into a hole in the kick shaft (bottom pic).
Attachments:
77 KZ 650 B1, 82 GPz 1100 B2.
Last Edit: 3 years 1 month ago by OnkelB.
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463146

Nelson wrote:
stranded for a week? you can push start it can't you?

Only if you put it together for me first, with all the pieces like the footpeg, then you push it off for me.

But because the clutch pack is mushy worn out, that probably won't work. But while we were kind of looking at it in disgust, we could smoke some Medical Marijuana for the emotional pain.
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463148

I don't guess I mind scraping gaskets much. This thing could have let go anywhere. Anyone ever read Zen and the Art of Motorcycle Maintenance? I did, a couple of times, and I think I feel a sequel coming along.

Gasket scraping = gumption building.

Builds character. Builds arm muscles and manual dexterity. Both good things, towards long term mental development.

Currently I M using a hacksaw blade in a stabsaw frame to peck away at the pieces of gasket still stuck to the case. NO easy access.

Anyone have any ideas besides mine?

I M going to send up some smoke signals.
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463152

Would putting it in some carb cleaner work? If it's just the case cover, shouldn't it fit in a pail of dip and bring the old gasket off in a bit?
Michael
1980 KZ1000 shaft drive
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463159

Well, back from gasket scraping.

I put it all kind of back together and I can see what happened.

Old, brittle plastic pieces part disintegrated, allowing spring to shift around outside of design parameters. Wiggled itself up out of the anchor point on the kick shaft.

SO it sits for a week, while I wait for a gasket, clutch pack (might as well do that chore since I can afford to this week) and plastic sleeve.

That stabsaw / hacksaw did a really good jub.

Has anyone every thought about or actually put two gaskets in place? My thinking on this is that the two gaskets wouldn't ever stick to each other, so it would allow for easier, damage free removal (Next time) hopefully never.
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463471

So anyone have any input on whether it's a good idea to use two gaskets, instead of one?
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463472

  • 650ed
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You don't need 2 gaskets. If you use 1 gasket but only put sealant in the area specified in the Kawasaki service manual there's very little to scrape off and there are no leaks. The service manual does not call for sealant on the whole gasket, just a little section. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463474

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KaZooCruiser wrote:
So anyone have any input on whether it's a good idea to use two gaskets, instead of one?

Reportedly, may fit two base gaskets when needed to reduce compression.

I seem to recall someone :unsure: -- maybe Larry C. :cheer: -- mentioned possibility of using a Scotch-Bright wheel to help remove base gasket residue.

Uncheap.:lol:

scotchbrightwheelad.jpg


Good Fortune! :)
Last Edit: 3 years 1 month ago by Patton.
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463497

KaZooCruiser wrote:
So anyone have any input on whether it's a good idea to use two gaskets, instead of one?

I figured ou this one on my own. It isn't a good adea, as it allows the sleeve to move outside of its design parameters, and flex is not an option.
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463542

Well HoRaY!

The clutch pack just arrived, and is now soaking in oil, and the sleeve showed up too. So I can put all that back together, awaiting the gasket. And while that is coming, I can reset the clutch cable and oil THAT.

Stay tuned.

/s
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463719

So now I have the cable oiled and back in place, and here I wait for a gasket.

The lines are open.

Anyone just use seam sealant, without a gasket?
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Search didn't work. . .neither does kickstarter 3 years 1 month ago #463822

So the gasket came in today, about 3pm. By 4, I had everything back together.

So I M out of here.

Rather live life than talk about it.
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