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Search didn't work. . .neither does kickstarter 14 Jul 2011 22:30 #462913

  • KaZooCruiser
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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 15 Jul 2011 08:51 #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
MIKUNI, RS-34'S...
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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Last edit: by Old Man Rock.

Search didn't work. . .neither does kickstarter 15 Jul 2011 09:49 #462984

  • KaZooCruiser
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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 15 Jul 2011 15:22 #463022

  • KaZooCruiser
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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 16 Jul 2011 01:12 #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
MIKUNI, RS-34'S...
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
The following user(s) said Thank You: KaZooCruiser

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Search didn't work. . .neither does kickstarter 16 Jul 2011 01:18 #463104

  • Patton
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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:
1973 Z1
KZ900 LTD

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Last edit: by Patton.

Search didn't work. . .neither does kickstarter 16 Jul 2011 01:29 #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
MIKUNI, RS-34'S...
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 16 Jul 2011 01:37 #463109

  • Nelson
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stranded for a week? you can push start it can't you?
Restoring and customizing a KZ1000. Click here to read about it.
Plated KTM, DR650, KZ1000, Former MC mechanic (eons ago). 40 yrs. of dirt and street.

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Search didn't work. . .neither does kickstarter 16 Jul 2011 07:35 #463127

  • OnkelB
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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).
77 KZ 650 B1, 82 GPz 1100 B2.
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Last edit: by OnkelB.

Search didn't work. . .neither does kickstarter 16 Jul 2011 12:00 #463146

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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 16 Jul 2011 12:08 #463148

  • KaZooCruiser
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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 16 Jul 2011 12:34 #463152

  • Chaotic Reason
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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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