ok...I run a small shop that usually works on Harley Davidson...But a lady brought me her 93' Vulcan and said it won't shift at all. So I thought I might be able to help her out since everyone else seemed to want to charge her an arm and a leg. As you all know and as I found out very quickly this is a little more work than I thought. So....to speed up this story and why I need help.....the engine is out...just got done checking the clutch plates and they are about a mm past the service limit...so theres problem number one. Now that the clutch plates are out it still does not shift so I know I need to split the cases. Once I split the cases is where I need some help......Can you guys suggest what the problem might be or could this be anything in the trans. ? Somthing else I'm not used to...am I going to have to buy the tool that removes the spark plug sleeve to get these heads off or is there another way that i'm not seeing? Thanks for your help all is appreciated!!!

I was able to get through the gears once by turning the motor a few revolutions but now it only stays in one gear and will not lock into the next it just kinda sits on one of the points of the shift drum cam.

i think this is gonna be a lance question but bedind the transmission cover there is a shift prawl... and a lil gear does that seem to be functioning?? im about to split the cases myself in fact i'm about to the point of the cases commming apart if u need any pics of things when i get there pm me and i'll do my best..., how much play is in the shift rod ?are the two circlips between the stator cover and the crank case?

Welcome to the forum MotoMedic. I can`t offer much help with what to look for inside the cases, but you can access a Kawi service manual at www.tocmanufacturing.com . Click on products and go down to other links. It is a big pdf file with exploded drawings and parts numbers for each model year. The photos it contains are not very clear but it has some good text. Most members here get a Clymers manual to use along with the Kawi pdf file.

The spark plug retainer can be removed using a thick 27 mm nut as a hex wrench. You don`t indicate if you are in the USA or a metric using country. The 27mm is a bit loose on my bike. A 1 1/16" nut would be 26.9875mm and a 1 1/8" = 28.575mm. So you might be able to use a 1 1/16" nut or file down a 1 1/8" nut to work for you.

That`s about all I can help you with. Other members will have more help to offer I`m sure.

I don't know these bikes very well yet either, but there are links to download the complete factory service manual from toc mfg website for free on here if you search for it.

Hang in there MotoMedic! There are quite a few folks that have cracked their motor, and they'll pitch in here soon. Most of em are probably doing their day job so be patient, you will be helped. This forum is a group of helpers, I can assure you!

Cool guys....I havn't split the cases yet because I wasn't sure about the spark plug sleeve..but now that I know that part I can move forward. As far as the shift rod there are 2 circlips in place and there is about 1/2 an inch play. Once I split the cases I will let you guys know more and take some pix....oh and I did download the manual before I started on the blike...thank God. I can disassemble and reassemble a V-Twin with my eyes closed but this is a different beast..lol

i think this is gonna be a lance question but bedind the transmission cover there is a shift prawl... and a lil gear does that seem to be functioning?? im about to split the cases myself in fact i'm about to the point of the cases commming apart if u need any pics of things when i get there pm me and i'll do my best..., how much play is in the shift rod ?are the two circlips between the stator cover and the crank case?
The shift prawl seems to be working fine the tranny is just not doing it's thing.

The shift prawl seems to be working fine the tranny is just not doing it's thing.

Does the shift drum cam seem to be turning smoothly? Is the roller on the gear position lever turning freely?

There is a bearing between the shift drum and shift drum cam that could have failed.

Cool guys....I havn't split the cases yet because I wasn't sure about the spark plug sleeve..but now that I know that part I can move forward. As far as the shift rod there are 2 circlips in place and there is about 1/2 an inch play. Once I split the cases I will let you guys know more and take some pix....oh and I did download the manual before I started on the blike...thank God. I can disassemble and reassemble a V-Twin with my eyes closed but this is a different beast..lol

There should not be that much play, that will cause shifting problems. There should be no more than 1/8" of play, one of the circlips must of moved out of the groove.

There is a bearing between the shift drum and shift drum cam that could have failed.
well when I got it to shift all through the gears that one time it seemed to be rolling fine. I havn't checked the bearing yet..can that be checked without splitting the cases?...I don't think this lady is prepared for how expensive this is gonna be. With the clutch and the gaskets alone she is over $200....I'm still not sure what I'm gonna charge for labor......any suggestions? Keep in mind when I took this job I told her that I would not charge an hourly rate because she was having some hard times...and I feel for her ...all she wants to do is break away for a while and ride..we have all been there. But it's gonna cost her...

There should not be that much play, that will cause shifting problems. There should be no more than 1/8" of play, one of the circlips must of moved out of the groove.
it's moving that much with the case off....not sure if that matters?? hey can I post a short video on here?? I'll show you guys exactly whats going on...

does the shift rod have a stopping point in the motor? because I went to put the shift pedal on so I could shift the bike and it moved farther down into the engine and the circlip came out of it's groove.....

it's moving that much with the case off....not sure if that matters?? hey can I post a short video on here?? I'll show you guys exactly whats going on...

I don't know about the video, it doesn't matter cover on cover off it should not move that much.

I don't know about the video, it doesn't matter cover on cover off it should not move that much.
So...I need to crack the case and look at that first...thanks for the info...all help has been much appreciated!

So...I need to crack the case and look at that first...thanks for the info...all help has been much appreciated!

If you can pull shift rod out the inner clip is off, if you can push it in the outer clip is out of place.

You will need a 18mm X 1.5mm X 60mm bolt to pull the rotor and the left side balancer bolt is left hand threads. :smiley_th

You will need a 18mm X 1.5mm X 60mm bolt to pull the rotor and the left side balancer bolt is left hand threads. :smiley_th
yeah i figured it was left hand threads....thanks for the info...i'll check some stuff out tomorrow and get back to you...