Shifter Shaft Problem - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 8 (permalink) Old 09-24-2016, 04:56 AM Thread Starter
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Shifter Shaft Problem

My shift shaft moves in/out 3/4" to 1". Am I missing a circlip or something? All I see when the stator cover is off is a washer, I believe there might be a circlip behind it, but maybe there's one on the inside of the motor to restrict movement?

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post #2 of 8 (permalink) Old 09-24-2016, 05:27 AM
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There should be two circlip/washer pairs on the shifter shaft under the stator cover.
From the outside in, it should be: shift lever spline, washer, circlip, section of shaft through empty space, circlip, washer, engine wall (leading to another cavity on the other side)
If both circlips are in place there shoudn't be an inch of play. There are grooves on the shaft for the circlips, so you should be able to tell where they go even if they're missing.
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post #3 of 8 (permalink) Old 09-25-2016, 06:48 PM Thread Starter
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So I pulled the cover back off after cleaning the engine, and the washers and circlips are all there. However, the shaft won't out far enough to get the inner circlip back in its groove. I'm wondering if the shaft got moved in and can't move back out because of interference with another part. Hopefully it's not the oil pump chain guide. Any ideas?

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post #4 of 8 (permalink) Old 09-25-2016, 08:00 PM
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Was the bike ever dropped? There is a piece that can bend a bit in there, but still function fairly normally

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
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Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
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V&H Cruzers
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1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

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post #5 of 8 (permalink) Old 09-25-2016, 08:10 PM Thread Starter
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It appears to have been dropped on the right side, but not the left. I think it would still function fine if I left it alone, it just bugs me having movement in that shaft. I could add a collar/spacer on there so the shift lever doesn't rub the frame. At least it still shifts fine.
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post #6 of 8 (permalink) Old 09-25-2016, 08:11 PM Thread Starter
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It's damn close too. If I could pull that shaft 1-2mm more I could get that circlip back on.

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post #7 of 8 (permalink) Old 09-25-2016, 11:17 PM
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Quote:
Originally Posted by thtanner View Post
Was the bike ever dropped? There is a piece that can bend a bit in there, but still function fairly normally
Are you talking the shift linkage rod? If it bent sideways it could rub against the housing...

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Originally Posted by mcinturff View Post
It's damn close too. If I could pull that shaft 1-2mm more I could get that circlip back on.
Hate to say it 'cause you probably already know it, but don't use force! A sleeve spacer sounds like a pretty good alternative to splitting the engine to see what it's hanging on on the other side.

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post #8 of 8 (permalink) Old 09-25-2016, 11:39 PM Thread Starter
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Looking at the 4 minute mark onward in this video, it doesn't seem like there would be anything holding it back except the oil pump chain guide.


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