1977 400 Triple

[pipeguy]

Hi guys thanks for addition to forum, here is my project.......P.O. powdercoated frame and rebuilt motor or just top end. But i see new gaskets in clutch cover....., i opened top end and there are new pistons. Looks like a 1 mm overbore there is a 1 stamped on top of pistons. The P.O. said he was in process of rebuilding and had to move a few times and had nowhere to store it so he got rid of it. Engine had no oil in it so i added some oil, got small leak at clutch cover. the wiring wasnt even properly routed, he just put everything together quick just to sell as complete bike. I noticed it wont shift into gear, its in neutral. |What coud be cause of this  tried rocking back and forth and still wont engage. should i take clutch cover to investigate? I cleaned carbs and got her to fire up!!! battery still holds charge! She only runs about 4000rpm, gotta fiddle with carbs i guess. needs about 10 kicks to get some sort of commitment to start, ans i have to find happy medium to get it going. Here are some pics of my progress so far.                                                                                                                                                               

[givr]

One possible scenario: If the engine has been dry for awhile, or rebuilt without lubing the shift drum, the shift forks may not move easily. I would fill the engine as high as you can with oil and Let it sit for a while. Then tilt the bike back and forth. Then Pull the plugs and turn it over to whip some oil up to the shift drum. Gently toggle the shifter.
Once it shifts, drain the oil to the proper level and make sure no tranny oil is in the crank recesses.

[pipeguy]

Thanks givr, but by having engine running a bit wouldnt oil spread everywhere?

[givr]

The engine isn't running, the plugs are out to ease turning it over with the kickstarter. Leave the ignition off. Kicking speed might not do much, now that I envision the gears turning, but it may. Just a suggestion.

[zambia]

There's a chance the clutch plates are stuck - that would impede shifting

[Walms]

I'm leaning toward what Givr said, likely seized shift drum with no oil present. Since clutch cover leaks, I'd take it off to investigate further

[pipeguy]

will shoot for this weekend.....but gotta replace my tach seal on my cb750 first.....thanks guys.

[nsman]

Does't the engine have to be running to shift from N or 1st into 2nd on the S series engines?

[shiloh]

No

[mraxl]

Jul 15, 2017 6:16:15 GMT -5 nsman said:

Does't the engine have to be running to shift from N or 1st into 2nd on the S series engines?

kawatriple.com/manuals/sseries/sman42.htm

[Curtis]

Just my own personal opinion, and take it as you will. Being a 40 year old 2 stroke, I would want to tear the engine down for an inspection and reseal, doing this could prevent a catastrophic failure.

Case in point - my 1978 KZ (four stroke yes) engine. Failed leak down test on cylinder 3, off with its head to re and re valves and cut new seats in, re ring as well, but turned into a junk crank with a failed rod bearing.

If I had not performed this inspection, and had just tried to run it. I could have further damaged the engine and not been able to save the cases.

[shiloh]

What curtis said, better safe than sorry.
Its fun ripping these engines down.

[zedixe13]

90-120W rear axle oil is great for smoother shifting .

[pipeguy]

Looks like previous owner already split cases, thats why i am hesitating in doing it again.....

[pipeguy]

Another question, by boring an extra 1 mm for all 3 cylinders, what would be the true cc?