replacing the shift shaft and linkage. - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 17 (permalink) Old 06-26-2013, 07:54 PM Thread Starter
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replacing the shift shaft and linkage.

OK as defacto mechanic for some of my friends I got asked to help with a shifting problem. The shift shaft just wobbles there and has about an inch and a half of travel in and out. Sounds like a broken linkage to me. So I'm sure this has been discussed at great length but I was wondering if someone could help me get a parts list together for this project. What gaskets will I need and are there any other parts to get besides the shaft and linkage?

I did do some searching around first and didn't find what I was looking for. I feel that I can do a writeup on this procedure for anyone else who has to make the repair. Lots of pics and everything. So please let me know what I'll need to do this.

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1988 Pontiac Trans Am (project/driver)

Last edited by M_Angell; 06-27-2013 at 06:39 PM.
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post #2 of 17 (permalink) Old 06-26-2013, 08:10 PM
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Parts needed would be the tie rod (shafts should be okay unless they were majorly abused) gaskets for the side covers, reccomend balancers, head and base gaskets, and a couple of 12mm circlips. You shouldn't need much else but a little permatex for the case halves and assembly lube, maybe consider the water pump bearings and seals as well as the shift shaft seal. Sorry for rambling but I'm going through my mental list of what was needed and what I did extra.

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post #3 of 17 (permalink) Old 06-26-2013, 08:13 PM
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Quote:
Originally Posted by M_Angell View Post
OK as defacto mechanic for some of my friends I got asked to help with a shifting problem. The shift shaft just wobbles there and has about an inch and a half of travel in and out. Sounds like a broken linkage to me. So I'm sure this has been discussed at grest length but I was wondering if someone could help me get a parts list together for this project. What gaskets will I need and are there any other parts to get besides the shaft and linkage?

I did do some searching around first and didn't find what I was looking for. I feel that I can do a writeup on this procedure for anyone else who has to make the repair. Lots of pics and everything. So please let me know what I'll need to do this.
The play in /out is a missing 13mm Cir-Clip which is suppose to hold the Shift Shaft outward. If that is the only problem, use a 1" piece of fuel line, slice it lengthwise ...placing over shaft, thus holding shaft outward. Worked for me 5K+ miles - - 2-3 years.

If tranny not shifting, probly 5mm Shift rod linkage ...replaceable with 8mm rod and case splitting. If splitting cases, suggest replacing shift rod seal along with every O'ring you disturb. Harbor Freight has a Metric 300pc case assortment for $5.50 . Also will need Stator case (nearly round) gasket, Generator cover gasket, clutch cover gasket, two dounut exhaust manifold gaskets (other exhaust gaskets (2 - goat belly 2- muffler) will not be needed if entire exhaust is removed from under bike as one piece) .
EDIT: In viewing Shark88's list, I see I left a few out ! LOL
hope this helps

Last edited by WilliamTech; 06-27-2013 at 03:28 PM.
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post #4 of 17 (permalink) Old 06-26-2013, 09:50 PM Thread Starter
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I just did the balance dampers. Lol don't want to do the head gaskets as they are fine. I'm really just looking for a list of gaskets I'll need to replace the whole assembly as. I might see if I can find some circlips at work. The PO of the bike half assed a lot of things on this bike so its been a little bit of a project.

2003 vn750
1988 Pontiac Trans Am (project/driver)
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post #5 of 17 (permalink) Old 06-27-2013, 12:33 PM
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This was posted on awhile back.
11009-1511 ***** GASKET,CYLINDER BASE x2
11004-1135 ***** GASKET-HEAD x2
11009-1474 ***** GASKET,GENERATOR COVER x1
11009-1475 ***** GASKET,TRANSMISSION COVER x1
11009-1512 ***** GASKET,CLUTCH OUTSIDE COVER x1
11009-1561 ***** GASKET,CLUTCH COVER x1
11009-1510 ***** GASKET,GEAR CASE x1

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post #6 of 17 (permalink) Old 06-27-2013, 12:44 PM Thread Starter
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Lol I must have not used the right keywords. I went through about 5 pages of two different searches. Thanks for the info.

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post #7 of 17 (permalink) Old 06-27-2013, 01:07 PM
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Quote:
Originally Posted by shark88 View Post
This was posted on awhile back.
11009-1511 ***** GASKET,CYLINDER BASE x2
11004-1135 ***** GASKET-HEAD x2
11009-1474 ***** GASKET,GENERATOR COVER x1
11009-1475 ***** GASKET,TRANSMISSION COVER x1
11009-1512 ***** GASKET,CLUTCH OUTSIDE COVER x1
11009-1561 ***** GASKET,CLUTCH COVER x1
11009-1510 ***** GASKET,GEAR CASE x1
Suggest adding the Shift Shaft Seal to this list......

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post #8 of 17 (permalink) Old 06-27-2013, 06:44 PM
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I think the shaft seal 92051-005

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post #9 of 17 (permalink) Old 06-28-2013, 01:17 AM
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If the head gaskets were not bad and they are the metal type there is no need to replace them I did my shift shaft for a grand total of 75 bucks in parts oil and beer my bike has shifted perfect and hasn't leaked a drop of nuthin since the repairs

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post #10 of 17 (permalink) Old 06-30-2013, 03:18 AM
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Quote:
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If tranny not shifting, probly 5mm Shift rod linkage ...replaceable with 8mm rod and case splitting. If splitting cases, suggest replacing shift rod seal along with every O'ring you disturb.
ok so ive been doing research on my stator change as well as balancers and i have a question...

when pulling the motor and doing this task will i be splitting the caseat all?
if so i would like to go ahead and upgrade the shift rod
where do i get the 8mm rod?

if not can i change the seal on it anyway?
i figure if i got the motor out i would like to seal it up as much as i can as it leaks on the left side from the sight glass cover

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