TOPIC:

When tearing down my KZ 650 I made a very stupid mistake, I pulled the shift rod more than 1.5" out.


According to Clymers this will cause the shift forks to fall to the bottom of the oil pan and require a complete teardown to reposition them.
However, they did not fall to the bottom of the oil pan. I have broken the engine down as far as you can without splitting the cases and turned it every which way and no shift froks!
Is it possible that they remained in position even when the rod was pulled, and is there any way to check for proper positioning before I reasseble the motor?

THANKS, I really don't want to have to do a complete teardown.

Are you sure you really pulled the shift fork shaft? It´s the one directly below the output shaft, circled in red in the pic below.

Thank you much for your help!
Thankfully that is not wat I pulled. I have not even pulled the cover off the output shaft as shown in the picture. I pulled the rod which sticks out directly in front of the shift lever, I guess it would be directly in the center just below where the photo cuts off.
Maybe I am looking at the manual wrong, (I hope so).
I will try and post a pic tomorrow.

Post edited by: Leonard Smalls, at: 2006/09/14 18:28

Post edited by: Leonard Smalls, at: 2006/09/14 18:30

No problem, you´re welcome. The rod you pulled is the clutch push rod that pushes on the clutch lifter plate - it can be removed and reinstalled without further ado, so nothing to worry about.


Nice nick btw, loved that movie.

"Name is Smalls, Leonard Smalls. My friends call me Lenny - only I ain´t got no friends".

I guess that is the worm gear pusher I pulled out, which is supposed to be able to slide out easily.
It is very confusing the way it is labeled the the clymers manual. Thanks for your help though!

Post edited by: Leonard Smalls, at: 2006/09/14 18:57

That´s it - if you look in the Clymer manual on pg. 115 you can see the pushrod in fig. 28, bottom left on the page.