Help a motorcycle newb with a 1985 Kawasaki Z450?

jake1978 · 11-07-2005

Hi all,

I was given an 85 Z450 to use as a training bike. Tonight when I was riding, as I downshifted to first, the shifter peg felt like it stripped, and fell slack. I checked it out at home and if you toy with it, it will still shift, but there is absolutely no tension. It just falls down limp. The linkages underneath are still intact, and appear to be fine, so I guess either the shifter itself is stripped or the mechanism attaching it to the linkage is broken.

Sorry for all the super technical terms.

I have ZERO motorcycle mechanical knowledge.

Any ideas, suggestions?

Thanks,
Jake

Jeff.saunders · 11-07-2005

It may be as simple as the return spring breaking. I do not have any diagrams for this bike - this model was not imported into the USA. Assuming the bike is based on the kz440 model, the fix should be a simple one if you can get the spring.

jake1978 · 11-07-2005

Maybe it is a 440. I could have been given incorrect info.

Are there diagrams available for this bike online, or elsewhere, or will I have to buy a shop manual?

Thanks,
Jake

MotorBone · 11-07-2005

Try BuyKawasaki.com

http://www.buykawasaki.com/Default.a...D=2&intParts=0

jake1978 · 11-07-2005

Thanks for the BuyKawasaki.com link. It was helpful.

It's definitely not a broken spring. I don't even have a spring. Either the shifter, or the shaft is stripped, I just don't know which.

Any idea of a part cost on the shifter?

dropdfocus · 11-08-2005

Only if the spline on the shaft is stripped or the inside of the shifter arm, there is a simple & inexpensive fix to this...
Reposition the arm back to were you feel it was at stock location. Now run a Sharpie line down the outside edge of the arm & shaft so if it falls or moves you can align it back up with the Sharpie marks.
Now you can take a drill bit and drill straight down through both parts (arm & shaft). The trick is not to drill too large of a hole that you remove too much material and weaken the shaft. You are now ready to insert a grade 8 (for strength purposes) bolt down through your hole you drilled and put some blue Loc-Tite on the end of the bolt. Thread the nut on and allow the Loc-Tite to dry & harden.

I did this on my old 125 dirt bike back in the day & it worked just perfectly.

Just my $.02 worth on the matter.

hogeater · 11-15-2005

heres another fix,, If the shifter lever is stripped on the shaft do this /take the shifter off the bike and install a long enough bolt through the lever to get a pair of vicegrips on it once tightened down (vicegrips on the threads side). tighten the bolt down to pull the gap back together tight, take a hacksaw and cut through the lever and bolt at the split, then remove the remaining bolt with the vicegrips, reinstall the lever on bike with new bolt ,this causes it to tighten down more. GOOD LUCK

11-07-2005	#1 (permalink)
jake1978 Newbie Join Date: Nov 2005 Posts: 3	Help a motorcycle newb with a 1985 Kawasaki Z450? Hi all, I was given an 85 Z450 to use as a training bike. Tonight when I was riding, as I downshifted to first, the shifter peg felt like it stripped, and fell slack. I checked it out at home and if you toy with it, it will still shift, but there is absolutely no tension. It just falls down limp. The linkages underneath are still intact, and appear to be fine, so I guess either the shifter itself is stripped or the mechanism attaching it to the linkage is broken. Sorry for all the super technical terms. I have ZERO motorcycle mechanical knowledge. Any ideas, suggestions? Thanks, Jake

11-07-2005	#2 (permalink)
Jeff.saunders Obsessed by Z1's BTK Expert Join Date: May 2005 Location: Upstate NY Posts: 304	It may be as simple as the return spring breaking. I do not have any diagrams for this bike - this model was not imported into the USA. Assuming the bike is based on the kz440 model, the fix should be a simple one if you can get the spring. __________________ jeff@z1enterprises.com 1973 turbo'd Z1, 1973 stock Z1 www.z1enterprises.com

11-08-2005	#6 (permalink)
dropdfocus Lowridin' Minitrucker BTK Expert Join Date: Jun 2004 Location: Williamsport, PA Posts: 1,204	Only if the spline on the shaft is stripped or the inside of the shifter arm, there is a simple & inexpensive fix to this... Reposition the arm back to were you feel it was at stock location. Now run a Sharpie line down the outside edge of the arm & shaft so if it falls or moves you can align it back up with the Sharpie marks. Now you can take a drill bit and drill straight down through both parts (arm & shaft). The trick is not to drill too large of a hole that you remove too much material and weaken the shaft. You are now ready to insert a grade 8 (for strength purposes) bolt down through your hole you drilled and put some blue Loc-Tite on the end of the bolt. Thread the nut on and allow the Loc-Tite to dry & harden. I did this on my old 125 dirt bike back in the day & it worked just perfectly. Just my $.02 worth on the matter. __________________ Jason Rymell '80 KZ750 LTD (H1): Cafe Racer / Sport Bike PA Kawi forum rides ROCK!! Last edited by dropdfocus : 11-08-2005 at 12:05 AM.

11-15-2005	#7 (permalink)
hogeater Newbie Join Date: Nov 2005 Location: Richlands,NC Posts: 20	shifter heres another fix,, If the shifter lever is stripped on the shaft do this /take the shifter off the bike and install a long enough bolt through the lever to get a pair of vicegrips on it once tightened down (vicegrips on the threads side). tighten the bolt down to pull the gap back together tight, take a hacksaw and cut through the lever and bolt at the split, then remove the remaining bolt with the vicegrips, reinstall the lever on bike with new bolt ,this causes it to tighten down more. GOOD LUCK

11-07-2005	#3 (permalink)
jake1978 Newbie Join Date: Nov 2005 Posts: 3	Maybe it is a 440. I could have been given incorrect info. Are there diagrams available for this bike online, or elsewhere, or will I have to buy a shop manual? Thanks, Jake

11-07-2005	#4 (permalink)
MotorBone The Bone Master BTK Beginner Join Date: Oct 2005 Location: Warren, Michigan Posts: 48	Try BuyKawasaki.com http://www.buykawasaki.com/Default.a...D=2&intParts=0

11-07-2005	#5 (permalink)
jake1978 Newbie Join Date: Nov 2005 Posts: 3	Thanks for the BuyKawasaki.com link. It was helpful. It's definitely not a broken spring. I don't even have a spring. Either the shifter, or the shaft is stripped, I just don't know which. Any idea of a part cost on the shifter?

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)