Shift Linkage / Transmission will not engage

Troutbum · 08-06-2008

Hi all - I'm going to start a new thread on this. I just replaced a motor on a 1981 kz550 LTD (the old one threw a rod). The new motor is in, started up, and runs fine. But, I can't drive anywhere because the transmission will not engage. Don't think the transmission is the problem, because it is definitely shifting between 1st and neutral - I can feel that with the foot pedal and the neutral light goes on and off - however, the sprocket / drive chain does not engage when in first gear. It's as if the clutch is in and I can't disengage it.

A few questions - Should the pin that is engaged by the clutch rocker spin while the motor is running? (It's not) Also - that pin does not "bottom out" against anything in the engine - I can push it into the engine with no resistance. Is that right? Does the clutch rocker engage the clutch by stopping that from spinning?

Is this a problem with the shift linkage? Do I need to go in behind the sprocket and see what's going on in there with the connection to the transmission? Or is it a clutch disengagement issue ?

I really appreciate the folks on here - Thanks -

StarGate · 08-06-2008

No the rod doesn't spin. Sounds like you have issues with the pressure plate and or it's movement. I would remove the clutch plate cover and see whats going on.

LoudFastUgly · 08-06-2008

Clutch plates like to seize together if unused for some time. open the clutch up and have a look

Troutbum · 08-06-2008

Thanks - I will open the clutch up tonight.

Troutbum · 08-12-2008

No wonder! (Sheepish Grin) - I took the clutch cover plate off, and there was no clutch assembly. Apparently the shop that sold me the used engine parted out the clutch and forgot about it, or just neglected to tell me about it. So, I'm going to swap out the one from the old engine.

However, I can't get the clutch hub nut off - the clutch wheel spins freely, and I can't seem to stop it sufficiently to allow enough torque to get the nut off. I think I'll have to take it to a shop and have them take it off.

Thanks -

08-06-2008	#1 (permalink)
Troutbum Newbie Join Date: Jan 2008 Location: Redmond, Oregon Posts: 12	Shift Linkage / Transmission will not engage Hi all - I'm going to start a new thread on this. I just replaced a motor on a 1981 kz550 LTD (the old one threw a rod). The new motor is in, started up, and runs fine. But, I can't drive anywhere because the transmission will not engage. Don't think the transmission is the problem, because it is definitely shifting between 1st and neutral - I can feel that with the foot pedal and the neutral light goes on and off - however, the sprocket / drive chain does not engage when in first gear. It's as if the clutch is in and I can't disengage it. A few questions - Should the pin that is engaged by the clutch rocker spin while the motor is running? (It's not) Also - that pin does not "bottom out" against anything in the engine - I can push it into the engine with no resistance. Is that right? Does the clutch rocker engage the clutch by stopping that from spinning? Is this a problem with the shift linkage? Do I need to go in behind the sprocket and see what's going on in there with the connection to the transmission? Or is it a clutch disengagement issue ? I really appreciate the folks on here - Thanks - __________________ Yenzo '81 KZ 550 LTD and A dumb minivan because I've got kids

08-06-2008	#2 (permalink)
StarGate Navy Vet S.A.R. crew BTK Expert Join Date: Apr 2007 Location: NE Arkansas Posts: 5,028	No the rod doesn't spin. Sounds like you have issues with the pressure plate and or it's movement. I would remove the clutch plate cover and see whats going on. __________________ Mike Original Owner 1981 KZ1000-K1 LTD 2000 Suzuki King Quad Photos

08-06-2008	#3 (permalink)
LoudFastUgly Got KZ? BTK Expert Join Date: Oct 2007 Location: Ontario Kanata Posts: 882	Clutch plates like to seize together if unused for some time. open the clutch up and have a look __________________ KZ550A4

08-06-2008	#4 (permalink)
Troutbum Newbie Join Date: Jan 2008 Location: Redmond, Oregon Posts: 12	Thanks - I will open the clutch up tonight. __________________ Yenzo '81 KZ 550 LTD and A dumb minivan because I've got kids

08-12-2008	#5 (permalink)
Troutbum Newbie Join Date: Jan 2008 Location: Redmond, Oregon Posts: 12	No wonder! (Sheepish Grin) - I took the clutch cover plate off, and there was no clutch assembly. Apparently the shop that sold me the used engine parted out the clutch and forgot about it, or just neglected to tell me about it. So, I'm going to swap out the one from the old engine. However, I can't get the clutch hub nut off - the clutch wheel spins freely, and I can't seem to stop it sufficiently to allow enough torque to get the nut off. I think I'll have to take it to a shop and have them take it off. Thanks - __________________ Yenzo '81 KZ 550 LTD and A dumb minivan because I've got kids

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