Bevel Gear/ Clutch Release Problems - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Transmission / Rear End
\ Chattering Clutch? Transmission Trouble?
Rear End Woes? Splines Shot? Discuss it here!

 
LinkBack Thread Tools Display Modes
post #1 of 3 (permalink) Old 06-05-2018, 01:38 PM Thread Starter
Member
 
Join Date: Aug 2014
Posts: 30
iTrader: (0)
 
Bevel Gear/ Clutch Release Problems

Okay so quick backstory. I did the engine tilt on my bike to replace a stator & rotor and I am currently slapping everything back together.

I have read through all the posts about people having problems installing the bevel gear and then having no tension on their clutch release lever. Well I have uninstalled and reinstalled this thing about two and a half dadgum times now and can’t seem to get this thing right.

The first time I installed it I definitely heard a loud “pop” when I was tightening down the bevel gear bolts. I prayed it was nothing big and kept installing it. After I had gotten all the bolts tightened back down the clutch release lever would not budge at all. I figured whatever the clutch push rod sits against in the bevel gear housing was stuck too far out So I took it off again and moved the lever till the “thing the clutch rod sits against” was in it’s lowest position.

Then I reinstalled the bevel gear and now the clutch release lever spins with NO tension in either direction for a lot of degrees and then there will be smidge of resistance (like the shaft finally hits something) and then it slips past it and spins with no tension again in either direction. It just “doesn’t feel right”.

This is how I think it works: When you pull the clutch lever at the handle it pulls the clutch release lever which turns the release shaft and the little splines at the top of the shaft push against the clutch push rod, and then what happens??? Is it possible I messed something up on the other end of the clutch rod, and that is why I am getting no resistance??

The Kawasaki manual made it seem like all of this should have been so easy….but I feel like I am missing the secret sauce of how this works, and am now worried I broke something.

2002 Kawasaki Vulcan 750
1979 VW Bus/Westfalia
KFred09 is offline  
Sponsored Links
Advertisement
 
post #2 of 3 (permalink) Old 06-05-2018, 02:10 PM Thread Starter
Member
 
Join Date: Aug 2014
Posts: 30
iTrader: (0)
 
I don’t know if this is relevant to my current situation or not, but I also do not believe I disconnected the clutch cable from the release lever the way I am seeing it tells me to in the Kawasaki manual.

I knew I was going to be taking the generator side cover off anyway so I just removed the little clutch cable mounting bracket on the lower right side of the generator cover and once that came off I was able to slip the cable out of the clutch release lever.

(I may also remember hearing a loud “pop” sound when I was taking off that little mounting bracket for the clutch cable, but it was more than a week ago so the details are getting foggy on me)

2002 Kawasaki Vulcan 750
1979 VW Bus/Westfalia
KFred09 is offline  
post #3 of 3 (permalink) Old 06-05-2018, 02:23 PM Thread Starter
Member
 
Join Date: Aug 2014
Posts: 30
iTrader: (0)
 
I went ahead and removed my clutch release shaft just to take a look and see if I could understand this beast a little better and it looks like on of the teeth may be tiny bit bent. Is this going to be a big problem?

I attached a picture of the clutch release shaft as reference.
Attached Thumbnails
Click image for larger version

Name:	20180605_110242 Small.jpg
Views:	35
Size:	95.9 KB
ID:	44642  

2002 Kawasaki Vulcan 750
1979 VW Bus/Westfalia
KFred09 is offline  
Sponsored Links
Advertisement
 
Reply

Bookmarks

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

Once registered, your User Name"cannot be changed". We can make exceptions within 7 days, but after that, it is set in stone.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome