Help needed with rewiring - Page 3 - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Electrical
Where does this wire go?
Includes Electrical mods, Lights, Stator,
Rectifier, Diagrams, etc

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post #21 of 54 (permalink) Old 01-17-2019, 10:08 PM Thread Starter
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Quote:
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Can't be tension on the cable if the lever won't return by itself. It sounds like the actuator rod isn't actually pushing the clutch.

Doesn't the rack inside the bevel gear have to be in a certain position before the bevel case goes back on?

The shaft on the release arm rotates and moves the rack inside the bevel gear case, the rack pushes the actuator rod into the clutch. It's a rack and pinion setup.
Is the gear that i turned clockwise suppose to return clockwise after pulling the cluck handle?

If so I'll check it tomorrow. Its getting pretty late here.
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post #22 of 54 (permalink) Old 01-17-2019, 10:32 PM
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Quote:
Originally Posted by Panarock View Post
Is the gear that i turned clockwise suppose to return clockwise after pulling the cluck handle?

If so I'll check it tomorrow. Its getting pretty late here.
Yes, it should turn clockwise when the clutch handle is released.

The rack isn't broken is it? Or did the rack fall out of the bevel case? It's not on the floor too, is it?

The rack is in the middle of the bottom row in this pic, just a flat bar with teeth on it:


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Last edited by Spockster; 01-17-2019 at 10:37 PM.
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post #23 of 54 (permalink) Old 01-17-2019, 10:40 PM
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Question: Did you put the clamp bolt back in the release arm before you tried pulling the clutch?

Just asking because the arm can slip to the wrong position if it's not clamped tight.

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post #24 of 54 (permalink) Old 01-17-2019, 10:45 PM Thread Starter
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Quote:
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Quote:
Originally Posted by Panarock View Post
Is the gear that i turned clockwise suppose to return clockwise after pulling the cluck handle?

If so I'll check it tomorrow. Its getting pretty late here.
Yes, it should turn clockwise when the clutch handle is released.

The rack isn't broken is it? Or did the rack fall out of the bevel case? It's not on the floor too, is it?

The rack is in the middle of the bottom row in this pic, just a flat bar with teeth on it:

I have never even seen it, is it behind the bottm left one on the picture? Or can it fall out if I open the case?

Also I havnt put the bolt back in in all my try's
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post #25 of 54 (permalink) Old 01-17-2019, 10:59 PM
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Quote:
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I have never even seen it, is it behind the bottm left one on the picture? Or can it fall out if I open the case?

Also I havnt put the bolt back in in all my try's
No, it's in the middle, at the bottom of the pic. Just a flat bar with teeth that engage the gear of the shaft.

Yes, it can fall out or just out of place. I think that's what's happening here.

But, with no clamp bolt on the release arm, it can slip and cause the same problem. You might have felt it slipping the first try, like the cable was jerking?
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post #26 of 54 (permalink) Old 01-18-2019, 07:04 AM Thread Starter
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Can you show me on the pictures where im suppose to find it? I cant find it myself and think I lost it

Can you show me on a order chard what the part is? I looked for it but cant find it

also, where is the spring that turnes the cog clockwise when releasing the handle?
Because I havnt opened the part of the bevel case that contains that. just the parts as shown on the pictures
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post #27 of 54 (permalink) Old 01-18-2019, 09:53 AM
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I've looked around and the release rack doesn't show in any parts diagrams I've seen yet. No pics in the manual, just one mention of it.

The spring action comes from the 5-6 springs on the clutch basket, on the right side of the engine. That long release rod pushes against those springs and those springs push back on the entire assembly, as I posted earlier.

For now, I need you to try this:

Look at the third pic in your post #26. See the round item inside the case, right side of the pic? Put one finger on that round piece, then rotate the release shaft back and forth. Does the round piece move in/out when you rotate the release shaft?

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post #28 of 54 (permalink) Old 01-18-2019, 10:08 AM Thread Starter
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It does
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post #29 of 54 (permalink) Old 01-18-2019, 10:13 AM
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Two things I think could have happened:

If the round piece doesn't move ... 1) When the bevel gear was installed without the release rod, the release rack may have slipped off the gear on the release shaft and the release rack is sitting in the bevel case behind the access cap. Access cap is bottom left in the pic I posted. You're going to need to be very careful if you have to take that apart. Refer to the manual.

OR

Round piece moves ... 2) The release lever was slipping on the release shaft when you tried the hand lever, because it wasn't clamped.

It's also going to have an oil leak from the bevel case due to the broken gasket and no sealer.

2003-21k mi
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post #30 of 54 (permalink) Old 01-18-2019, 10:14 AM
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Quote:
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It does
I think the release lever was slipping because it wasn't clamped tight.

2003-21k mi
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__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
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