I had a total resto 1980 KZ1000 nearly kill me two + years ago. 25 days in hospital, 5 surgeries. 99% back!! I have never been afraid of bikes and still am not, but my life has changed. I gave it up. Peace. R
Its pressed onto the crank. You need the appropriate rotor puller tool. In the 🇺🇸 they are easy to come by for 20 to 40$ the puller screws in the crank end and then exerts force to pop off the rotor. Do not bang the rotor, not even a rubber mallet. Sometime they can be difficult. Do not heat. Consult the manual for your bike model. Happy wrenching.
what engine stand are you using. I removed and disassembled my kz550M (shaft) for a loud noise in low rpm which to me sounded like a spun bearing. However, I haven't found anything wrong on the bottom end and everything works as it should. I am just having a lot of difficulty putting the cases back together and I see you put the bottom onto the top where as I was trying the opposite (do not recommend). But I cant flip without a stand like this one.
dealer.klsupply.com/general-equipment/k-l-mc25-metric-engine-stand.asp That is the link for the engine stand I used. I sold it several years ago. Great stand! The ability to flip the engine is a great aid at dis and reassembly. You may have to go to a 3rd party supplier, as they are in demand. Noise as a specific RPM would indicate clutch, drive shaft, motor mount or frame problems IMHO. Happy wrenching!
Hello Ron. You know what you're doing with this engine. I also have a GPZ550. Unfortunately with a non-functioning 2nd, 3rd, 4th, and fifth gear. First gear is the only one that works. What could that be ? It's a difficult job to inspect ? Can you give me some advice please ?
Rob Dijkhuizen Hi Rob. I need to know more. When you say the other gears don't work please describe. bike won't shift at selector or it shifts and gears don't work? The only way to inspect is to split the cases. if it is the first you may have just some busted selector linkage external or internal. If the latter I would guess you have some mangled shift forks and dogs. Also if you mean that you can't move thru gears and are trying to do that without the engine running that's normal. The Kawasaki neutral finder mech will not allow you to shift past 1st gear without the motor running. There are ballbearings in the tranny counter shaft that expel with centrifugal force when the the motor is running and then it will shift normal. Another tip. go-to KZRider.com lots of experts there will help. R
Thank you for your answer. I bought the GPZ550 a week ago (in Holland. I also live in Holland). The guy who sold it to me said it wasn't running. it had stood stil for at least one year. The battery was completely dead.Carbs had to be cleaned. So i haven't started the bike yet. When i put in first gear, i can feel the bike engaging the gear. When i try to move it, i can hear it's in gear. i hear the pistons move. When i put the gear lever upwards, it goes to neutral. No problem here. But when I want to select the next gear upwards, the second gear. It won't engage. It will not "fall"into 2nd gear. Maybe it will when the engine is running ? I had no idea this was a kawaski issue. All other bikes i've had could switch through gears, even when ignition is off.
www.partzilla.com/parts/search/Kawasaki/Motorcycle/1981/KZ550-D1+GPz/TRANSMISSION/parts.html That's an 1981 parts diagram and the one you see at part #600 is the ball bearing I mentioned. That is the Kawasaki neutral finder feature. In my opinion you are fine. You will not be able to cycle gears by hand without the motor running. U R good! Get a factory service manual, the info is in there. Good luck! R
I allready found a servicemanual on manuallib.com. But your diagram also helps. I'm glad to know this is normal behaviour. You know, I'm riding motorbikes for 17 years now. i've had many different types of motocycles, but this Kawa is the first with this (in my eyes) "peculiar" behaviour. Once again, many thanks. You've me helped me a lot. really appreciate that.
very good video and excellent motorcycle
Thanks, love those old KZs. R
Thanks pal, I’ve got one.
Enjoy it. Happy wrenching!
If I had too many good bikes ... I kept making videos like this from Argentina
I had a total resto 1980 KZ1000 nearly kill me two + years ago. 25 days in hospital, 5 surgeries. 99% back!! I have never been afraid of bikes and still am not, but my life has changed. I gave it up. Peace. R
How'd you remove/install the alternator rotor? Your video cuts exactly where I needed it!
Thanks
Its pressed onto the crank. You need the appropriate rotor puller tool. In the 🇺🇸 they are easy to come by for 20 to 40$ the puller screws in the crank end and then exerts force to pop off the rotor. Do not bang the rotor, not even a rubber mallet. Sometime they can be difficult. Do not heat. Consult the manual for your bike model. Happy wrenching.
@@WisconsinTroutFishing thank you, you're a legend!
what engine stand are you using. I removed and disassembled my kz550M (shaft) for a loud noise in low rpm which to me sounded like a spun bearing. However, I haven't found anything wrong on the bottom end and everything works as it should. I am just having a lot of difficulty putting the cases back together and I see you put the bottom onto the top where as I was trying the opposite (do not recommend). But I cant flip without a stand like this one.
dealer.klsupply.com/general-equipment/k-l-mc25-metric-engine-stand.asp
That is the link for the engine stand I used. I sold it several years ago. Great stand! The ability to flip the engine is a great aid at dis and reassembly. You may have to go to a 3rd party supplier, as they are in demand. Noise as a specific RPM would indicate clutch, drive shaft, motor mount or frame problems IMHO. Happy wrenching!
Hello Ron. You know what you're doing with this engine. I also have a GPZ550. Unfortunately with a non-functioning 2nd, 3rd, 4th, and fifth gear. First gear is the only one that works. What could that be ? It's a difficult job to inspect ? Can you give me some advice please ?
Rob Dijkhuizen Hi Rob. I need to know more. When you say the other gears don't work please describe. bike won't shift at selector or it shifts and gears don't work? The only way to inspect is to split the cases. if it is the first you may have just some busted selector linkage external or internal. If the latter I would guess you have some mangled shift forks and dogs. Also if you mean that you can't move thru gears and are trying to do that without the engine running that's normal. The Kawasaki neutral finder mech will not allow you to shift past 1st gear without the motor running. There are ballbearings in the tranny counter shaft that expel with centrifugal force when the the motor is running and then it will shift normal. Another tip. go-to KZRider.com lots of experts there will help. R
Thank you for your answer. I bought the GPZ550 a week ago (in Holland. I also live in Holland). The guy who sold it to me said it wasn't running. it had stood stil for at least one year. The battery was completely dead.Carbs had to be cleaned. So i haven't started the bike yet. When i put in first gear, i can feel the bike engaging the gear. When i try to move it, i can hear it's in gear. i hear the pistons move. When i put the gear lever upwards, it goes to neutral. No problem here. But when I want to select the next gear upwards, the second gear. It won't engage. It will not "fall"into 2nd gear. Maybe it will when the engine is running ? I had no idea this was a kawaski issue. All other bikes i've had could switch through gears, even when ignition is off.
Oh btw thanks for the tip about KZrider.com !!
www.partzilla.com/parts/search/Kawasaki/Motorcycle/1981/KZ550-D1+GPz/TRANSMISSION/parts.html
That's an 1981 parts diagram and the one you see at part #600 is the ball bearing I mentioned. That is the Kawasaki neutral finder feature. In my opinion you are fine. You will not be able to cycle gears by hand without the motor running. U R good! Get a factory service manual, the info is in there. Good luck! R
I allready found a servicemanual on manuallib.com. But your diagram also helps. I'm glad to know this is normal behaviour. You know, I'm riding motorbikes for 17 years now. i've had many different types of motocycles, but this Kawa is the first with this (in my eyes) "peculiar" behaviour. Once again, many thanks. You've me helped me a lot.
really appreciate that.
i just need that,,,i disamble motor,,i i need help...
Thanks Damir and good luck.
enpä noin paskaa videoo kattonu pitkään aikaan , siis todella ala-arvoinen kuvaus
Suomi on ruosteinen, mutta jos et pitänyt videosta, niin voi. Hyvää jakoavainta!