Gear change lever assy replacement - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 10 (permalink) Old 03-06-2015, 05:06 PM Thread Starter
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Gear change lever assy replacement

Anyone ever changed the gear lever assy that comes out of the case? I have a fairly abused (not by me) 86 model that looks like someone ground this lever off to where there aren't even any splines left. I can't get the jury-rigged lever back on where they ground it flat.
Thanks in advance.
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post #2 of 10 (permalink) Old 03-06-2015, 06:42 PM
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while I am not 100% certain.. I believe that is going to require pulling the engine and splitting the case..

but I am not positive

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post #3 of 10 (permalink) Old 03-06-2015, 06:56 PM
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Sounds about right. I believe you have to get to the clips by splitting the cases...that's a whole teardown.

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post #4 of 10 (permalink) Old 03-06-2015, 11:04 PM
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I hate to say it.... Weld it now, fix it later if you need to? Doesn't sound like welding would hurt it at this point.

The lever sounds like it needs some file work to go back on the shaft.

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post #5 of 10 (permalink) Old 03-07-2015, 07:29 AM
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yes that requires a complete engine tear down

if you want to ride the bike any time soon just weld it

if you want to fix it right i have the whole gear change mechanism for sale

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post #6 of 10 (permalink) Old 03-07-2015, 11:34 AM
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Would jb weld be strong enough?mix it up,put some on the splines and the shifter,assemble and let cure.might be worth a try

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post #7 of 10 (permalink) Old 03-07-2015, 11:52 AM Thread Starter
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I think you are all correct. I am NOT tearing the engine down . I think I will cut the lever at the collar, weld a 1 inch extension and ride on! BTW, the splines were ground off too. FUN!
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post #8 of 10 (permalink) Old 03-07-2015, 01:23 PM
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There was a post on here a while back about a guy who did it without splitting the cases,but can't find it for the life of me.I have an 86 motor with the same problem

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rejetted for K/N Pods part#rc 2340
sportster seat

'I didn't lose my mind.i gave it away

BRING BACK WOLFIE."Peace and Carrots"RIP
"And I'm free...as a bird"John Lennon Free as a Bird
"I only carry when I have my pants on"Joe Robinson RIP aka Old Dog
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post #9 of 10 (permalink) Old 03-08-2015, 09:57 AM
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The one post I remember was putting the spring clip back on, at the rear end of the shift rod at the shift drum. He fished around through those holes and got it back in place. Not sure if that's the only post.

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__________________________________________________ ____________
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post #10 of 10 (permalink) Old 03-11-2015, 11:14 PM Thread Starter
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How much for your gear change assy? Do you have any pics? It would help me visualize what the whole contraption looks like and how this tear down will go.
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