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KZ200 shifter not working

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30 Jul 2024 19:11 - 30 Jul 2024 19:20 #902667 by RossH
KZ200 shifter not working was created by RossH
Hi everyone,

Just as I was getting excited that my bike was finally running well, it's gotten stuck in 2nd gear. The shifter pedal isn't catching anything. It moves up and down to the extreme limits of its range with little friction and whether or not the clutch is engaged. The pinch bolt attaching it to the shaft is tightened fully. Any ideas? I'm nervous that it is something major and that I'll have to dive into the engine, something I've never done before.

Any help is appreciated.

Ross
Last edit: 30 Jul 2024 19:20 by RossH.

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31 Jul 2024 06:44 - 31 Jul 2024 06:45 #902674 by TexasKZ
Replied by TexasKZ on topic KZ200 shifter not working
When you move the shift lever, can you see the end of the shaft moving with it?

Could be a broken return spring. It is reference number 23 in the diagram.

www.partzilla.com/catalog/kawasaki/motor...ear-change-mechanism

It could also be the mechanism is fouled up with dried and semi-dried chain lube and dirt.

I would remove the shift lever and the sprocket cover and clean everything in there really well and see what’s up.

Keep in mind that the Kawasaki Neutral Finder will prevent you from choosing any gears other than first and neutral while the motorcycle is stationary.


 

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/11-projects/620336-anoth...uild-thread?start=24
Last edit: 31 Jul 2024 06:45 by TexasKZ.

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31 Jul 2024 10:11 #902685 by RossH
Replied by RossH on topic KZ200 shifter not working
Yes, the shaft moves with the lever. 

I will check behind the sprocket cover and clean it this weekend when I get some time. Thanks!

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07 Aug 2024 15:49 #902847 by RossH
Replied by RossH on topic KZ200 shifter not working
I finally got around to checking this. After taking off the right side engine cover, I found that the spring that you mentioned is not broken and still works. The shift pedal snaps back to the center if you move it up or down, but it will not change gears. The clutch is still working because I have to pull it to move the bike. Any further ideas?

Thanks,
Ross

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12 Aug 2024 15:32 #903168 by RossH
Replied by RossH on topic KZ200 shifter not working
After digging more into the whole shifting mechanism, I found the problem. Referencing the diagram linked above, a piece broke off of the shifting shaft (part 24), and that piece holds the C-shaped lever (part 25) in place. That's why I couldn't shift. Found a replacement shaft on Ebay.
The following user(s) said Thank You: Wookie58

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12 Aug 2024 19:03 #903175 by TexasKZ
Replied by TexasKZ on topic KZ200 shifter not working
Glad it is a simple fix.

Thanks for letting us know.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/11-projects/620336-anoth...uild-thread?start=24

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