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Discussion Starter #1
So I am in the process of replacing the stator on a 91 vulcan and now that i have it back together I am afraid I might have done something wrong. I put the bevel gear back on how i took it off with no problems but when i went to go hook the clutch cable up there was no resistance at all in the lever that goes through the bevel case. I went to the clymers manual and adjusted the lever and gear accordingly but there is still no resistance on the lever. It will just spin whichever way i want it too. Im trying to figure out if this is a problem or if I am missing something. I have not put oil in or ran it at all, but is this something that will go away once im done or did i screw something up. Thanks for all the help.
 

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I dont think you got the clutch release shaft installed all the way, you forgot to or misplaced the release rack, you didn'y put the clutch rod back in (doubtful), and last did not instal the clutch springs. Check in that order. Good luck.
 

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Our nomenclature is different because I am using a kawasaki service manual. the bevel gear you speak of is what I am refering to as the release rack.
 

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There is also a seating surface for the clutch rod to sit on that goes in the bearing on the clutch hub. Without it the rod will slide through the bearing.
 

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Just to clarify, because I have been up for about 20 hours at work. did you take the clutch apart?
 

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i do not understand were the clutch came to place in you stator replacement since i do not find it necassary to have removed the front bevel gear? I still think the shaft was not seated all the way or you misplace the release rack, but disregard post 3 and 4 I thought you replaced your clutch as well. Take some pics.
 

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remove your clutch lever on the engine and rotate the shaft clock wise until it stop then reinstall the lever about 70 to 80 degrees in reference to clutch line. pretty much pointing right towards the engine. and it should work correctly.
 

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Discussion Starter #8
I did not remove the clutch to do the stator. I removed the 90degree gear housing on the back left side of the engine. The beggining of the shaftdrive. The lever clutch lever that goes through there is what seems to be spinning freely. I adjusted that accordingy to the maual and it does not seem to work. It looked like it connected to a rod that went entirely throught the engine to the clutch side. The rod did slide out a bit when i pulled the bevel gear housing off. Is it possible that that rod did not go into the proper place when reassembled. I am not sure where it goes to on the other side of the engine. The rod is part M in the picture above. You say there is a bearing it connects to and will slide through it if not in the right place. Maybe that is what i did. Would it be best to take the clutch side off to reinstall that rod?
 

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I do not believe the part that it sits would have fell out. When you put the shaft that you say spins infinate was there any gap between the lever and where it meets the bevel gear case? If the is a noticable gap approch 1inch the shaft is not seated. If there is no gap I feel you are missing the release rack which is small geared bar that appears to be about 1 inch. This piece goes right behind the plug on the bevel case. I will take pic when I get home for you
 

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The rod rides inside the hollowed transmission mainshaft with very tight clearances, so it would be impossiblein my own opinion to be inserted wrong especially since you did not fully remove it. That why I do not believe that piece circle on the exploded view fell out. Your problem has to be there locally at the bevel gear.
 

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Discussion Starter #11
Well i suspected the same thing with hopes that i did something wrong on assembly. I took the release rack and everything apart and redid it all. It works. I think I may have turned the shaft the wrong way when putting the gear back in which caused the loose lever. Either way it is working fine and i appreciate all the help. You gave me a much better understanding how it all works. Thanks for everything.
 
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