Shifter pedal loose - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 17 (permalink) Old 06-04-2016, 03:37 PM Thread Starter
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Shifter pedal loose

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Noticed recently that shifting has gotten harder, on and off. Sometimes it's normal, other times it requires a lot more effort.

Checked the shifter just now and it has a lot of play in and out. Anyone experienced this before? I assume that when it's all the way out, it's harder to shift, and vice versa.

My bikes:
2017 Kawasaki Z1000SX Tourer
2002 Suzuki DR-Z400S
1999 Yamaha Dragstar 1100
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post #2 of 17 (permalink) Old 06-04-2016, 04:28 PM
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There are two thin washers that ride on the shifter shaft inside the case. Their purpose is limiting in/out travel of the shaft.

Either yours have broken off, or someone has left them out when the engine was taken apart. It's easy to miss the outer one when it drops out as the case is removed.

Some have used a piece of rubber fuel hose slid over the shaft to limit travel to the inside. You may find posts about here if you're lucky with the search. Not sure how you could limit the outward travel, however. Outward may not be a problem, try the hose for a temporary fix.

What is happening, the internal linkage hits other internal parts of the engine/trans when the shaft slides out of place.
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Last edited by Spockster; 06-04-2016 at 04:31 PM.
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post #3 of 17 (permalink) Old 06-05-2016, 05:19 AM Thread Starter
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Quote:
Originally Posted by Spockster View Post
There are two thin washers that ride on the shifter shaft inside the case. Their purpose is limiting in/out travel of the shaft.

Either yours have broken off, or someone has left them out when the engine was taken apart. It's easy to miss the outer one when it drops out as the case is removed.

Some have used a piece of rubber fuel hose slid over the shaft to limit travel to the inside. You may find posts about here if you're lucky with the search. Not sure how you could limit the outward travel, however. Outward may not be a problem, try the hose for a temporary fix.

What is happening, the internal linkage hits other internal parts of the engine/trans when the shaft slides out of place.
Thanks for replying.
Doesn't sound as bad as I feared, at least.. Is it risky to ride it around when it's like this?

My bikes:
2017 Kawasaki Z1000SX Tourer
2002 Suzuki DR-Z400S
1999 Yamaha Dragstar 1100
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post #4 of 17 (permalink) Old 06-05-2016, 10:23 AM
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Originally Posted by Python View Post
Thanks for replying.
Doesn't sound as bad as I feared, at least.. Is it risky to ride it around when it's like this?
Not sure, but could be. If you can't get through the gears reliably, I'd be careful pulling into traffic.

I'm always leery of anything that can cause catastrophic engine failure while riding. Just not sure what sort of interference the internal linkage can cause.

I would at least get a piece of hose on there to eliminate half of the problem.

I'll see if I can find a post on it so you'll know what length to try.

edit: Going by the posts I found, a spacer on the outside will let it shift reliably. Here's some links, including the search I used, and one picture link.

Rubber hose, rubber washers, plastic spacers, pvc pipe, or a hose clamp have all been used with success. Hose clamp may tend to wear on the case. Looks like 1 1/16" is the length used for a spacer.

Search:
https://www.vn750.com/forum/gtsearch....755j8755339j12

Pics:
http://s652.photobucket.com/user/tou...tml?sort=6&o=4

Posts:
https://www.vn750.com/forum/26-transm...de-play-2.html

https://www.vn750.com/forum/26-transm...ter-pedal.html

https://www.vn750.com/forum/26-transm...e-shifter.html
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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; 06-05-2016 at 10:49 AM.
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post #5 of 17 (permalink) Old 06-05-2016, 02:48 PM
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Read this
https://www.vn750.com/forum/26-transm...s/18271?page=1
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post #6 of 17 (permalink) Old 06-05-2016, 03:25 PM
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Quote:
Originally Posted by Spockster View Post
There are two thin washers that ride on the shifter shaft inside the case. Their purpose is limiting in/out travel of the shaft.

Either yours have broken off, or someone has left them out when the engine was taken apart. It's easy to miss the outer one when it drops out as the case is removed.

Some have used a piece of rubber fuel hose slid over the shaft to limit travel to the inside. You may find posts about here if you're lucky with the search. Not sure how you could limit the outward travel, however. Outward may not be a problem, try the hose for a temporary fix.

What is happening, the internal linkage hits other internal parts of the engine/trans when the shaft slides out of place.
YES ! Precisely true. I performed this fix. No need to remove Shift Pedal.........Split rubber hose is about 1 1/4" long holding shaft outward with maybe 1/8" in-outward free-play remaining ........works like a champ !
Many K miles with this DIY Fix.

- -

'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 #7 of 17 (permalink) Old 06-05-2016, 04:12 PM Thread Starter
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Quote:
Originally Posted by Spockster View Post
Not sure, but could be. If you can't get through the gears reliably, I'd be careful pulling into traffic.

I'm always leery of anything that can cause catastrophic engine failure while riding. Just not sure what sort of interference the internal linkage can cause.

I would at least get a piece of hose on there to eliminate half of the problem.

I'll see if I can find a post on it so you'll know what length to try.

edit: Going by the posts I found, a spacer on the outside will let it shift reliably. Here's some links, including the search I used, and one picture link.

Rubber hose, rubber washers, plastic spacers, pvc pipe, or a hose clamp have all been used with success. Hose clamp may tend to wear on the case. Looks like 1 1/16" is the length used for a spacer.

Search:
This is a discussion forum for the Kawasaki Vulcan VN750 and VN700 - Search Results for shifter play

Pics:
Plastic Spaces Close Up Photo by tourmax | Photobucket

Posts:
https://www.vn750.com/forum/26-transm...de-play-2.html

https://www.vn750.com/forum/26-transm...ter-pedal.html

https://www.vn750.com/forum/26-transm...e-shifter.html
Wow, thanks a lot. I'll try to fix it next weekend. Really appreciate the help.

Quote:
Originally Posted by OleDirtyDoc View Post
From the thread: "If all you did was knock off the clip inside the case, you can just pull the lever so it is as far out as you can pull it , then measure the space between the shifter lever and the case.

You just need to take off the shifter and install a spacer or a stack of washers that are add up to that measurement to keep the shifter from moving in towards the engine case."

So basically, the shifter is supposed to be all the way out? I thought it was the other way.

My bikes:
2017 Kawasaki Z1000SX Tourer
2002 Suzuki DR-Z400S
1999 Yamaha Dragstar 1100
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post #8 of 17 (permalink) Old 06-05-2016, 05:39 PM
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Not sure if I would pull it out all the way. Maybe try the 1 1/16" to 1 1/4" spacer mentioned in the threads.

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 #9 of 17 (permalink) Old 06-05-2016, 08:21 PM
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Quote:
Originally Posted by Spockster View Post
Not sure if I would pull it out all the way. Maybe try the 1 1/16" to 1 1/4" spacer mentioned in the threads.
Yup that's what I'd do

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Support your local FREEBIRDS MC
1986/5 Vn700/750 Frankenfook cross eyed bitch "Mellisa Fayhe"
I am a BIKER and i'm proud.FREEBIRDS MC CENTRAL NY

lowered with progessive 412 10" shocks
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 #10 of 17 (permalink) Old 06-05-2016, 11:04 PM Thread Starter
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Quote:
Originally Posted by Spockster View Post
Not sure if I would pull it out all the way. Maybe try the 1 1/16" to 1 1/4" spacer mentioned in the threads.
That means I have to open the cover, drain the oil etc so I can install a spacer in there?

Edit: "If all you did was knock off the clip inside the case, you can just pull the lever so it is as far out as you can pull it , then measure the space between the shifter lever and the case.

You just need to take off the shifter and install a spacer or a stack of washers that are add up to that measurement to keep the shifter from moving in towards the engine case."

From one of the threads. Seems like people in that thread recommended pulling it all the way out, then installing a boat load of washers, copper pipe, pvc pipe etc. Whatever that would hold it out - and let it have a little bit of play.

Sorry if I'm nagging, haha, but I'm just a month away from a very long trip where I'm visiting 3 countries. Kinda nervous doing this on an old ass bike, so I want it to be as tip top as possible.

My bikes:
2017 Kawasaki Z1000SX Tourer
2002 Suzuki DR-Z400S
1999 Yamaha Dragstar 1100

Last edited by Python; 06-06-2016 at 12:41 AM.
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