Splitted crankcase twice. Not shifting using the pedal. Too big gap -shaft and cam? - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 25 (permalink) Old 04-15-2016, 04:45 PM Thread Starter
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Question Splitted crankcase twice. Not shifting using the pedal. Too big gap -shaft and cam?

Any ideas? Soon no more hair on my head to pull out.. Crankcase splitted twice.
Too big gap between shift shaft and shift drum cam?
I can not figure out why not shift to second using the pedal.
Closeup ant end of video...
See video here: youtube.com/watch?v=SjL4PxDOVvo


Last edited by ihlebek; 04-15-2016 at 04:56 PM.
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post #2 of 25 (permalink) Old 04-15-2016, 05:03 PM
..have a vulcan good day!
 
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Quote:
Originally Posted by ihlebek View Post
Any ideas? Soon no more hair on my head to pull out.. Crankcase splitted twice.
Too big gap between shift shaft and shift drum cam?
I can not figure out why not shift to second using the pedal.
Closeup ant end of video...
See video here: youtube.com/watch?v=SjL4PxDOVvo

https://www.youtube.com/watch?v=SjL4PxDOVvo
Sorry, unable to offer any idea's.

Your Shift Pawl Lever tips look like new........
Did not notice any worn parts......

When did this start ? ....after an engine repair/rebuild (splitting cases) ?


'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 #3 of 25 (permalink) Old 04-15-2016, 05:11 PM
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Uh-oh....

Are you trying to shift to second with the bike just sitting there? Or did you have trouble when riding the bike?

Just sitting ... Kawi has positive neutral finder, will not go into 2nd unless the bike is moving a certain speed.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
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post #4 of 25 (permalink) Old 04-15-2016, 06:18 PM Thread Starter
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Quote:
Originally Posted by WilliamTech View Post
Sorry, unable to offer any idea's.

Your Shift Pawl Lever tips look like new........
Did not notice any worn parts......

When did this start ? ....after an engine repair/rebuild (splitting cases) ?

Thank you for reply :-)

Yes, after second splitting, was good after first splitting.

First time: Had to replace the left case half because of the left balancer bolt fell off when driving and damaged the crankcase, balancer gear and alernator rotor. I guess the previous owner forgot to use locktite on the bolt...

Second time: Had to replace water pump because of sloppy work by me with the snap ring...
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post #5 of 25 (permalink) Old 04-15-2016, 06:28 PM Thread Starter
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Quote:
Originally Posted by Spockster View Post
Uh-oh....

Are you trying to shift to second with the bike just sitting there? Or did you have trouble when riding the bike?

Just sitting ... Kawi has positive neutral finder, will not go into 2nd unless the bike is moving a certain speed.
Haha! :-)

Thank you for reply.

Yes that's truth unless you remove the front bevel gear case, and turn the damper cam by hand, fast enough.
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post #6 of 25 (permalink) Old 04-15-2016, 07:34 PM
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I'm not sure you turned it fast enough.

Did it stop shifting while riding?

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
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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post #7 of 25 (permalink) Old 04-15-2016, 07:49 PM Thread Starter
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Quote:
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I'm not sure you turned it fast enough.

Did it stop shifting while riding?
No, it was after the second splitting.

PNF: As you can se in the video, it works when I use the pilers, but the Shift Pawl can not touch the Shift Drum Cam when in neutral (1:20).

Last edited by ihlebek; 04-15-2016 at 07:52 PM.
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post #8 of 25 (permalink) Old 04-15-2016, 08:04 PM
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Originally Posted by ihlebek View Post
No, it was after the second splitting.

PNF: As you can se in the video, it works when I use the pilers, but the Shift Pawl can not touch the Shift Drum Cam when in neutral (1:20).
It's designed not to shift above neutral unless the bike is moving a certain speed. I'm not sure rotating that shaft by hand will do it.

The ball in the neutral finder is probably stopping the shift pawl from reaching 2nd. It hits 1st and neutral ok, and neutral is an upshift.

I can be wrong, but that's how it looks.

Any chance the PNF got misplaced during the work?

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

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

Last edited by Spockster; 04-15-2016 at 08:06 PM.
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post #9 of 25 (permalink) Old 04-15-2016, 08:32 PM Thread Starter
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Quote:
Originally Posted by Spockster View Post
It's designed not to shift above neutral unless the bike is moving a certain speed. I'm not sure rotating that shaft by hand will do it.

The ball in the neutral finder is probably stopping the shift pawl from reaching 2nd. It hits 1st and neutral ok, and neutral is an upshift.

I can be wrong, but that's how it looks.

Any chance the PNF got misplaced during the work?
OK! I understand what you mean according to PNF.

I belive this: (0:11) can not change to 2nd, even with the pilers. (0:13) can change to 2nd because the steel-balls has been sent away from the grooves in the output shaft, and into the holes in the gear.

...and yes, I have tried to shift to second while driving the testride after the second splitting. That's why I removed the transmission cover and bevel gear case for the third time.

Yes, it might happend, I'm only human... (hehe)

Last edited by ihlebek; 04-15-2016 at 08:34 PM.
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post #10 of 25 (permalink) Old 04-15-2016, 09:13 PM
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Ok, understood.

At :45, looking at the pawl and it's slot in the center, when you shift, the pin in the center contacts the bottom of the slot and it shifts.

Right after that, when you try to shift the other direction, it doesn't look like the pin contacts the top of the slot. That's when it won't shift.

I'm wondering if the internal linkage rod could be bent or out of adjustment (if any). ??

Maybe shift some more and verify if that pin can ever contact the the top of the slot. ??

Doesn't look like it's throwing the pawl far enough in that one direction. The shift drum and gears appear to be fine from this angle.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
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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