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TOPIC: Pops out of gear in second!

Pops out of gear in second! 30 Oct 2009 12:15 #330506

  • rkan
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Every once in a while, while I'm really letting it rip in second gear, it pops out of gear. I can shift back into it again right away but it is a little unnerving. Is it a sign of clutch wear? I ride a '78 650b
1978 KZ650B

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Pops out of gear in second! 30 Oct 2009 12:36 #330508

  • Mcdroid
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Uh, probably not a clutch problem...it is possible that is a bent shift fork. :(
Michael
Alvin, Texas

1982 GPz750
1977 KZ1000A
1978 KZ1000A
1982 GPz1100
1975 Z2A

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Pops out of gear in second! 30 Oct 2009 13:13 #330513

  • nads.com
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Sounds like second gear might need to be back cut or replaced. These are known for this, mine did it so bad shifting from 1st to sec on a wheelie, it would jerk back and forth rapidly. I back cut my own but wouldn't reccommend it. Always check the forks while it's apart. I couldn't use second gear on mine it got so bad.

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Pops out of gear in second! 30 Oct 2009 15:21 #330534

  • kawsakiman
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Congratulations!
Your about to get very well acquainted with your bike.
You need to split the cases to change either second gear or the whole transmission.
Second gear is the weak link in almost every make of motorcycle.
someday i will be able to afford my kz habit.

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Pops out of gear in second! 30 Oct 2009 15:57 #330538

  • bluej58
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I had that problem before with my 78 KZ1000 and had to split the cases.
When I did I found that the circlip had came off the shift rod because the groove was not cut deep enough.
An easy fix once I got to it.
Same symptoms, the bike would would still shift, but it would pop out when I was getting on it.
If this is the problem you will see it right away and it is just a matter of cutting a deeper groove and using a fresh circlip.
I am lucky to know a good machinist.
You don't have to pull out the gear cluster or anything real tricky.
And if somebody says you should dress up the first gear while you have it that far apart and he'll do it for cheap
"Don't do it", but thats a story for some other time.
Good luck JD
78 KZ1000 A2A

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Pops out of gear in second! 30 Oct 2009 16:38 #330552

  • timebomb33
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normally if a transmission is popping out of gear it means the shift dogs on that gear are worn out it most likley means second gear on both shafts will have to be replaced or at the very least if they aren't to badly chewed up undercut
1973 z1 2-1974z1-a,2-1975z1-b dragbikes1015cc+1393cc, 1977kz1000,1978kz1000,1981kz1000j, 1997 zx-11, 2000 z12r,1428turbo nitrous pro-mod and a shit load of parts thats all for now leader sask.,CANADA
I THINK MY POWERBAND BROKE

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Pops out of gear in second! 30 Oct 2009 17:39 #330555

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Hey rkan,
How many miles you got on that thing ?
78 KZ1000 A2A

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Pops out of gear in second! 09 Nov 2009 18:46 #332492

  • rkan
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It's got about 24k miles. Today it did it again right as i was about to shift at 8 grand and the motor wound up to maybe 11k rpm. My buddy behind me said that black smoke came out the exhaust right then.
1978 KZ650B

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Pops out of gear in second! 10 Nov 2009 06:35 #332600

  • Old Man Rock
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"i was about to shift at 8 grand"...

Am I understanding this correctly where your running in 1st gear up to 8Krpm to shift into second! :blink:
:pinch: :whistle:
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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Pops out of gear in second! 10 Nov 2009 14:11 #332671

  • racer54
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All the time! That's the fun part!:laugh:
1980 LTD (changed over the years), 1979 LTD (being rebuilt), 1977 KZ turbo and various KZ's in various states of build. KLX110

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Pops out of gear in second! 10 Nov 2009 14:13 #332672

  • rkan
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Haha well I was in 2nd gear about to shift into 3rd and it was on an on ramp.
1978 KZ650B

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Pops out of gear in second! 10 Nov 2009 16:35 #332688

  • PLUMMEN
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shift faster! :laugh:
Still recovering,some days are better than others.

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Pops out of gear in second! 10 Nov 2009 17:45 #332703

  • bluej58
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24,000 miles it's still a pup.
I can't believe the gears or shift forks are trashed all ready.
I'd put my money on the circlip coming off.
On my bike the shift rod had fell out of position but still shifted, but when I'd hammer 2nd it would pop out of gear
I think I had about that many miles on my 78 kz1000 at the time.
I wonder if the shift rods are the same type, from a bad batch.
What ever the problem is, I recommend you pull the motor and split the case and have a look before it screws something else up.
It isn't that bad to do I think I took it out one night and put it back together the next( I had a buddy help me) and hopefully all you'll need is that groove cut deeper and a new gasket.
Good luck and keep us posted. JD
78 KZ1000 A2A

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Pops out of gear in second! 11 Nov 2009 14:52 #332890

  • mark1122
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it could be a combo of the forks and the dogs, Oh and lets not forget the circlip.
any ways.u may be able to pull the pan and have a look see. u can pull the fork rod out and inspect it's groove, and the forks without pulling the motor.
u should be able to see enough of the dogs on the 2nd gears, from underneeth, to tell how bad they are.
if bad u should be able to find a good used trany cheap.
76 kZ, frame gusset work,1200CC.Ported by Larry Cavanaugh,This email address is being protected from spambots. You need JavaScript enabled to view it., 1.5mm.over intakes,.ZRX12 rear end,and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg,Ont.Can.

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