And the work finally begins - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 38 (permalink) Old 04-27-2013, 12:36 AM Thread Starter
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And the work finally begins

So I finally got into looking into my non functional shifter. I also decided it was time to take care of the other little things going not quite right last season, rattling gas cap, not working radiator fan, shot dust caps on the fork seals .....
So I took some pictures after remembering the posts on building the 2 into 1 exhaust that I hurried together and never took decent pics. then set it next to a stock system off the project/parts bike (more on that story in a different post) If there is any interest I can take more detailed pics of the whole thing.
During teardown I found a snapped throttle cable so there is another project. After getting the motor on the bench I pulled the side cover hoping that my problem was just the spring clip, not my luck. Looks like I have a case to split to get to the shift rod. I will try to keep this one updated as I get further into the second rebuild.
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87 vn750at least that is what the frame #'s say
"Squirrel Bike" aka Jersey

Rat bike with a good PR agent

shaved and coastered
2 into 1 exhaust
rear 170 and front 110
Relocated R/R
custom dash with voltmeter
Spitfire windscreen
Plutonium plugs
Recovered seat without "butt hammers"
More to come
Praise to the Parts Goddess Crobins for needed things

When someone tells me "Great minds think alike" all I can think is "You Pervert"
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post #2 of 38 (permalink) Old 04-29-2013, 10:28 AM
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looking forward to it.i love the term project/parts bike

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post #3 of 38 (permalink) Old 05-07-2013, 11:52 PM Thread Starter
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So I found a little more free time and started motor tear down. Verified that the shift rod did indeed snap and it will be a complete teardown. I would like to ask those that have split the cases, what all I should expect for parts needed? I was planning head and base gaskets and using permatex for the side cases, thinking about replacing rings and rod bearings while in there too. The clutch plates look almost new as do the balancers so I will reuse those. Ideas and suggestions are welcome. Pictures will be posted as I get some that don't look like giant dark blurs.

87 vn750at least that is what the frame #'s say
"Squirrel Bike" aka Jersey

Rat bike with a good PR agent

shaved and coastered
2 into 1 exhaust
rear 170 and front 110
Relocated R/R
custom dash with voltmeter
Spitfire windscreen
Plutonium plugs
Recovered seat without "butt hammers"
More to come
Praise to the Parts Goddess Crobins for needed things

When someone tells me "Great minds think alike" all I can think is "You Pervert"
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post #4 of 38 (permalink) Old 05-07-2013, 11:54 PM Thread Starter
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Quote:
Originally Posted by OleDirtyDoc View Post
....i love the term project/parts bike
The term comes from indecision and not knowing if I can replace the title. If I get a title back it becomes project, no title means parts. Right to the back burner for now.

87 vn750at least that is what the frame #'s say
"Squirrel Bike" aka Jersey

Rat bike with a good PR agent

shaved and coastered
2 into 1 exhaust
rear 170 and front 110
Relocated R/R
custom dash with voltmeter
Spitfire windscreen
Plutonium plugs
Recovered seat without "butt hammers"
More to come
Praise to the Parts Goddess Crobins for needed things

When someone tells me "Great minds think alike" all I can think is "You Pervert"
dragon159 is offline  
post #5 of 38 (permalink) Old 05-10-2013, 07:03 PM Thread Starter
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Now the cases are separated and I think I have a full list of everything needed. As promised here are more pics of what I found, not only did the shift rod break but it was bent beforehand. I also found a scuff on the rear skirt of the front piston, no big deal. A rough spot in the rear cylinder sleeve that should go after honing. One thing I really am unsure about is after pulling the shift shafts out it looks like they are bent too, but I have nothing to compare it to yet. Anyone who has been this far in please look and let me know if they are bent or workable.
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87 vn750at least that is what the frame #'s say
"Squirrel Bike" aka Jersey

Rat bike with a good PR agent

shaved and coastered
2 into 1 exhaust
rear 170 and front 110
Relocated R/R
custom dash with voltmeter
Spitfire windscreen
Plutonium plugs
Recovered seat without "butt hammers"
More to come
Praise to the Parts Goddess Crobins for needed things

When someone tells me "Great minds think alike" all I can think is "You Pervert"
dragon159 is offline  
post #6 of 38 (permalink) Old 05-10-2013, 08:09 PM
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How does that happen to the shift rod? Shifting extra hard or something? Maybe trying too hard to get the bike into something other than 1st or Neutral with it turned off? That's crazy.

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Originally Posted by LibertyPilot View Post
Leave it to me to NOT be fond of something then end up banging it.
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post #7 of 38 (permalink) Old 05-10-2013, 11:02 PM Thread Starter
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My only guess is it had something to do with the problems I had getting it into first, I had to get a little too aggressive at times. It did break trying to get first, so I will have to adjust my shifting habits some after repairs.

87 vn750at least that is what the frame #'s say
"Squirrel Bike" aka Jersey

Rat bike with a good PR agent

shaved and coastered
2 into 1 exhaust
rear 170 and front 110
Relocated R/R
custom dash with voltmeter
Spitfire windscreen
Plutonium plugs
Recovered seat without "butt hammers"
More to come
Praise to the Parts Goddess Crobins for needed things

When someone tells me "Great minds think alike" all I can think is "You Pervert"
dragon159 is offline  
post #8 of 38 (permalink) Old 05-31-2013, 12:55 PM Thread Starter
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So I dropped the jugs off at the machine shop. They are doing a rough bore to clean up the rear cylinder and figure out how big the overbore is going to have to be. Meanwhile I am scavenging off my parts motor the shifter stuff so hopefully I can get everything back together soon.

87 vn750at least that is what the frame #'s say
"Squirrel Bike" aka Jersey

Rat bike with a good PR agent

shaved and coastered
2 into 1 exhaust
rear 170 and front 110
Relocated R/R
custom dash with voltmeter
Spitfire windscreen
Plutonium plugs
Recovered seat without "butt hammers"
More to come
Praise to the Parts Goddess Crobins for needed things

When someone tells me "Great minds think alike" all I can think is "You Pervert"
dragon159 is offline  
post #9 of 38 (permalink) Old 05-31-2013, 01:06 PM
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Quote:
Originally Posted by Deviate View Post
How does that happen to the shift rod? Shifting extra hard or something?
I have seen a lot of riders that bounce the shifter when down shifting. It's meant to be pressed, not stomped. I mean, look at how long the shifter is from the toe plate to the shaft rod. A lot of pressure can be put on the lever in just a little to no effort. The eternal linkage rod gets bent during down shifting.
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post #10 of 38 (permalink) Old 05-31-2013, 04:39 PM
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If you are going to use the shift rod from another engine, make sure it is the newer, stronger version, otherwise, order a new one as they were improved

Cheman

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