'02 Clutch lever - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 8 (permalink) Old 02-11-2007, 06:51 PM Thread Starter
 
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'02 Clutch lever

Stupid, stupid, stupid! I had no business going out today...it was a beautiful sunny day, but too cold. But I was feeling so clautrophobic that I had to ride. Got the bike started without nearly as much trouble as yesterday (thanks to all the reading I've done here about the wonders of Sea Foam!) and got it out of the shed. Put the kickstand down and went to put the bike down on it when it slid back up. Of course the bike was too heavy for me to pull back up, so it went down. And, you guessed it, broke the tip off the clutch lever.
How hard would it be for a real newbie with limited knowledge of things mechanical to replace a clutch lever?
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post #2 of 8 (permalink) Old 02-11-2007, 09:56 PM
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A fairly easy job just need a new lever. Also a common way of droppping your bike I can assure you your not the first. Another common way of dropping one on the kickstand is to let the clutch out befire the engine stops turning if you are like me and like to park it in 1st gear.

Rckmtn
Dennis Huff
Cheyenne, Wy.
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post #3 of 8 (permalink) Old 02-11-2007, 11:22 PM
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The hardest part (and it's not really that hard) is getting the cable adjusted after the lever is changed.

First, you'll need to loosen the cable at the adjustment point (right where the cable goes into the lever)
To loosen it, screw it in as far as it'll go.

Next, remove the cable from the lever (line up the slot in the adjustment screw with the locking nut)

Remove the lever and reverse the above to install the new lever.

Take note of how much free play is in the lever before you remove it. Once all's back together, tighten the adjustment nut until it seems to be like it was, and see how the clutch works.

Any other questions, you know where to ask !!


AKA: Tim & 'The Adventure Cycle' VROC #24567, NEVROC, SteelCity VROC


"When life throws you curves,
Aim for the apex."

Author Unknown
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post #4 of 8 (permalink) Old 02-12-2007, 08:38 AM
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One little caution when replacing the clutch lever. Be mindful of the clutch lever bolt.
From the Vulcan verses..

"Ok.. Big Bikes come to the rescue.. Try a Goldwing Dealer. The clutch levers
are inter-changeable.. Starr has tried Goldwing clutch levers on mine with no
problem.. 8 mm main shaft part of bolt.. threaded part 5 mm. Ask for the one
for a GL1500.

In installing new levers - just be careful of that clutch lever bolt.. That seems to be the one that has broken for at least two others.. It's a shaft, with a threaded end and does have a nut attached. Parts diagram at buy kawasaki should show you . And I'm sure it's covered in the online manual too.
I snapped that puppy right off trying to put the lever back on - didn't even know it was there. It's the safety switch that keeps it from starting if it's in gear.

Mechmo was trying to install the Flanders levers today, and did exactly what
you warned him not to - snapped the plastic pin on the backside of the clutch
area. He saw it, thought he had cleared it, was wiggling the clutch, and heard it snap. Damn Mechmo! What is the pin for/what does it do, and how do I replace it?

That’s the clutch starter disengagee thing sounds like. Only cost abt $5
Next.. the "little plastic pin" is the clutch/starter safety switch. There should be two wires coming to it. The question is... does the circuit need to be open
(wires not touching) or does the circuit need to be closed (wires touching) for
the starter to work? One way to find out... try both. This can keep you riding
while ordering the replacement switch. The switch IS a good idea... starting in
gear, etc.
The switch prevents the bike from starting if it's in gear and the clutch is not
pulled in. Now that you have broken off the little plastic pin, your bike WILL try to start, and it will lurch forward if you inadvertently try to start it while it is in gear.

Well that Mechmo sure is an idiot! He did the same darn thing when he was at
my house once. Luckily, the switch is held in place by a single screw and takes all of 3 minutes to replace.

Dianna
Conway, AR
Patriot Guard Rider
2000 VN750 Sere (Serendipity)
1990 GL1500 (Ole Blue)
1986 VN750 EVie (project bike, heavy custom)
VROC # 11628 / 25000-H
ARVROC # 12 Coordinator and Crowd Control
OKVROC # 18 (H)
TNVROC # 45 (H)
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post #5 of 8 (permalink) Old 02-12-2007, 12:26 PM Thread Starter
 
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Okay, I was doing well until I got to that last post! I'm going to order the part, but I'm going to be asking lots of questions before I actually do the job.
I am determined to wean myself off the dependence on the ex bf. I can do this stuff- it ain't computer programming!
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post #6 of 8 (permalink) Old 02-12-2007, 01:47 PM
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No need for alarm.. The ones that did break it, did so cause they weren't aware of it being there.
You on the other hand have been told about it and will be looking out for it so won't have any issues with it!

(You'd be amazed at how fast you get past ex's once you have a part or two installed on your bike under your belt, and with the help of the VN750 gang!)

Dianna
Conway, AR
Patriot Guard Rider
2000 VN750 Sere (Serendipity)
1990 GL1500 (Ole Blue)
1986 VN750 EVie (project bike, heavy custom)
VROC # 11628 / 25000-H
ARVROC # 12 Coordinator and Crowd Control
OKVROC # 18 (H)
TNVROC # 45 (H)
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post #7 of 8 (permalink) Old 02-12-2007, 04:30 PM
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Even if you snap the plastic pin, it can be glued back together if you don't want to replace the switch. I used a piece of plastic from a model airplane kit and have had no problems at all.

Jim W
93 VN 750 "Ursula"
Moved R/R 08Sep06
R/R rewire 17Feb07
New R/R, Installed 14Jun08
New Stator installed 10 Jun08
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post #8 of 8 (permalink) Old 02-13-2007, 03:52 AM
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My switch hasn't worked since about a year after I got the bike.
I just have to be sure I'm in neutral when I want to start it. If it's in gear (even with the clutch in) it wont even turnover.
It was a bit annoying at first, but I've gotten used to it.


AKA: Tim & 'The Adventure Cycle' VROC #24567, NEVROC, SteelCity VROC


"When life throws you curves,
Aim for the apex."

Author Unknown
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