Teardown in my near future - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 6 (permalink) Old 11-07-2012, 01:03 AM Thread Starter
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Teardown in my near future

I was working on my bike the other night and was working on adjusting my shifter a notch lower because it was a bit high. As I was putting the shifter back on it was being stubborn, so I tapped the end of it with a small hammer, and you guessed it, I snapped the E-Clip on the shaft inside of the engine. 480 480J1300 CIRCLIP-TYPE-C,13MM Part number from the manual.
And now the shaft will go in the engine almost 2 inches. So I took a piece of hose from the hoses that go to the heads, (is a perfect size over the shift shaft for those who ever need to do it in the future for a quick fix) and so far it has held. I'm hoping to be able to do a tilt and remove the left side cover instead of doing a full pull. I have done an earshave so the plenum won't be in the way. I plan on putting a 2X4 under the lift on the left side to see if it will tilt it up far enough.
I'm going to drain my oil in hopes the clip will be near the screen, if not I will have to fish it out with a magnet. It's a never ending battle with these bikes.
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post #2 of 6 (permalink) Old 11-07-2012, 10:38 AM
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The c clip is probably still on the shaft. You probably just dislodged it from the groove in the shaft. Just sayin...

"Show me a man who makes no mistakes, and I'll show you a man who doesn't do things." Theodore Roosevelt."

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post #3 of 6 (permalink) Old 11-07-2012, 10:48 AM
..have a vulcan good day!
 
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Quote:
Originally Posted by TSmith68 View Post
I was working on my bike the other night and was working on adjusting my shifter a notch lower because it was a bit high. As I was putting the shifter back on it was being stubborn, so I tapped the end of it with a small hammer, and you guessed it, I snapped the E-Clip on the shaft inside of the engine. 480 480J1300 CIRCLIP-TYPE-C,13MM Part number from the manual.
And now the shaft will go in the engine almost 2 inches. So I took a piece of hose from the hoses that go to the heads, (is a perfect size over the shift shaft for those who ever need to do it in the future for a quick fix) and so far it has held. I'm hoping to be able to do a tilt and remove the left side cover instead of doing a full pull. I have done an earshave so the plenum won't be in the way. I plan on putting a 2X4 under the lift on the left side to see if it will tilt it up far enough.
I'm going to drain my oil in hopes the clip will be near the screen, if not I will have to fish it out with a magnet. It's a never ending battle with these bikes.
I discovered the same shaft issue years ago, rubber hose still in place. No issues / problems.

WilliamTech

'86 VN750 13,700 mi -Stock
-Purchased 2008 w/8800mi
Replaced ALL Cables . Kuryakyn LED Voltmeter
SilverStar Ultra 9003/HB2 H4 Headlamp, Jardine Fwd Controls,
Iridiums DPR7EIX-9 & Wires, Tuxedo Mod, Coil Mod, P/U Sensor Mod, Fork Seals,
Splines Lubed - 11/4/2012 - MF AGM Battery
Additional Flashing LED Brake Light on Trunk
Dampers went out @ 13+K !
After TOC MCCT's..... so amazingly quiet I discovered a rattling heat shield on my stock exhaust !
...have a vulcan good day!
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post #4 of 6 (permalink) Old 11-07-2012, 12:46 PM Thread Starter
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Thanks WilliamTech, I thought the rubber piece will stay in place for a long time, and I most likely won't repair it until this winter. I didn't think about the E-Clip still being on the shaft and getting dislodged, there isn't much holding it on there. I'm not sure if the 86 had the bigger shift rod in the case or not, and if the oil pump had the guide under the chain. If not I plan on replacing both of them while I'm in there. I know I don't have to split the cases to replace the E-Clip on the shift shaft, but if I pull the engine to replace it, I want to check the rest of the engine over to make sure it's in good shape for next years riding.
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post #5 of 6 (permalink) Old 11-09-2012, 01:39 AM
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Quote:
Originally Posted by TSmith68 View Post
Thanks WilliamTech, I thought the rubber piece will stay in place for a long time, and I most likely won't repair it until this winter. I didn't think about the E-Clip still being on the shaft and getting dislodged, there isn't much holding it on there. I'm not sure if the 86 had the bigger shift rod in the case or not, and if the oil pump had the guide under the chain. If not I plan on replacing both of them while I'm in there. I know I don't have to split the cases to replace the E-Clip on the shift shaft, but if I pull the engine to replace it, I want to check the rest of the engine over to make sure it's in good shape for next years riding.
if by shifter rod you mean the tie rod then it will only be the bigger more sturdy one if it has been replaced

but i know for sure the oil pump does have a guide i split the case on my 86 engine to stop the case from seeping oil and i do remember seeing that in there that is to say if in fact that was the original engine on my bike when i bought it

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post #6 of 6 (permalink) Old 11-10-2012, 01:57 AM Thread Starter
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That's what I meant new, The part that goes in the case to tie it all together.
I'm not sure what year they started going with the bigger shift linkage. I know the earlier type was prone to breakage and I end up tapping the shifter with my foot harder than I need to sometimes because it sticks. The weather here has turned for the worse, so riding is pretty much over for the year. Plus I will be putting in more time at work for the holidays so I won't have much time to work on it. It's a blessing to me tho, because I'm about ready to burn it to the ground.
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