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Hi, new to this forum but not new to Kawasaki, have a KZ440, too. Anyway, I was thrilled to get a great deal on my 06 VN750, drove it for 3 days when the weather finally allowed and then drove it home and down my long bumpy-assed driveway, went to get on it an hour later and the shifter just flops! It is stuck in first gear and there is about 80 degrees of play on the shifter up and down and at least 1/4" in and out. I had to drive it in first all 8 miles to town, very sad. I've always liked my Kawasaki's but this is pretty scary if it's going to happen a lot. I've seen possible Pawl Spring on here but wonder if this is a chronic problem with bumpy roads and what anyone thinks about my issue? Thanks for any replies...
 

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Just read it, thanks, now I gotta get this info to my mechanic...:doh:
 

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Hi, new to this forum but not new to Kawasaki, have a KZ440, too. Anyway, I was thrilled to get a great deal on my 06 VN750, drove it for 3 days when the weather finally allowed and then drove it home and down my long bumpy-assed driveway, went to get on it an hour later and the shifter just flops! It is stuck in first gear and there is about 80 degrees of play on the shifter up and down and at least 1/4" in and out. I had to drive it in first all 8 miles to town, very sad. I've always liked my Kawasaki's but this is pretty scary if it's going to happen a lot. I've seen possible Pawl Spring on here but wonder if this is a chronic problem with bumpy roads and what anyone thinks about my issue? Thanks for any replies...
This does not sound like a pawl spring problem. If it is just a pawl spring issue, the shift lever will not have 80 degrees rotation. This sounds more like a shift lever tie rod snapped or popped off. I hope not. Maybe the more experienced folks will chime in soon.

~~C8>
 

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Discussion Starter #5
Craaap...

Now I'm worried again, the thing definitely travels 5-6 inches at the end of the shifter. Still connected, tho, would it still travel that smoothly if it was broke?
 

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When my pawl spring got stuck, the gear shifter had normal range of motion and spring return, I just couldn't change gears. I was unfortunately stuck in neutral when it happened to me. I was really pissed. But the bike didn't care. First gear would have been great! The pawl spring acts more like a retaining spring than a tension or return spring.

The pawl spring is still the first thing to check (easy). As a matter of fact, it looks like if the pawl pulls away or falls off the change shaft, it might have the symptoms you describe.

But if the pawl spring area is ok, the next culprits are the gear change lever and the tie rod. Upload the service manual and look at the assemblies. The '06 isn't in there, but you can see the same in the '04.

Kanuck69 has a link to a service manual download in his signiture. It is a large file.

~~C8>
 

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It sounds like 2 different problems. It is not that uncommon for the shifter shaft to slide in and out quite a bit, especially if the bike has been dropped on the shifter. Something breaks inside the engine that allows the shaft to move in and out like that. Out is the proper position for it, and many people just install a spacer between the shifter and the case to hold it in that position. Pull the shifter all the way out, and see if it still has several inches of play in it. If so, you likely have a far more serious problem. There is a linkage rod inside the case that could have broken or come loose. Fixing it requires a complete engine teardown and splitting the cases. I hope that isn't it.

Your bike may have been the victim of a first time rider, or a bike abuser. Some riders will just stomp on the shifter, and that will usually cause serious internal damage. The shifting mechanism is a pretty delicate thing on most bikes.
 

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Discussion Starter #8
Thanks Jerry, I hope that isn't it, too, or my great deal suddenly looks pretty crappy. It only has 10K on it but I did let a big friend of mine ride it and he may not be as gentle on it as me. I may have to reconsider letting anybody else ride my bike...
 

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Update

Just an update, my problem isn't anything accessible from the outside, the shaft turns and the pawl spring is in place. My mechanic can't crack the case until late next week and I have none of the tools or skills to do it myself, so I guess we'll have to see what's wrong then. I'll try to post a final result and a couple pics when we find the problem.
 

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Wow, that really sucks. That means a complete engine teardown. Did you get a price on that?
 

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$500 labor and whatever on parts, possible carb kit while they're in there. I have a pretty good deal on mechanics, tho, don't quote that at a shop, they'll laugh at you... :)
 

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It appears that my shifter linkage shaft broke off inside of the trans. A complete teardown reveals that the chain in there was loose, allowing the thing to shear right off, very sad.
 

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Sorry to hear that buddy. Well ... glad you got some mechanic friends to help. Good luck with it.

~~C8>
 

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Discussion Starter #16
Got the shaft in, finally, but now I'm having a hard time finding a complete gasket set. Does no one carry a complete set? Looks like just ordering them one by one is the only way to do this, and, since it's completely torn down, I want to put it back right with as many preventative things as possible. Any suggestions?
 

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Discussion Starter #17
To answer my own question, I found the part number(11028-1098) in the archives here for the master gasket kit, found them in stock at Gearhead.com, and got them coming for $125 after shipping and tax. Yay gaskets!
 
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