Shifting Problems

 

I own a 1999 Kawasaki Vulcan 1500 Classic. Last week I was riding and heard
a clicking or rattling noise in 3rd gear. I parked the bike for several
days. I then rode it from my garage and after about 3 miles I am unable to
shift lower than 4th gear. I now only have 4th & 5th gears.

Any ideas or fixit ideas.

thanks.

 



http://webservices.motorsportdealers.com/parts/partImages/KUS/2/C18/C1857/E=
1370.Gif

These parts are accessible without going into the engine cases:

The 92081 hairpin spring returns the shifter lever to the central
position when you take your foot off the shifter. Sometimes these
springs break.

The 92153 eccentric bolt adjusts the shifter mechanism. Sometimes the
eccentric bolt breaks or loosens up and falls out, then the shifter
doesn't work.

The 92144A spring is another spring that can break.


http://webservices.motorsportdealers.com/parts/partImages/KUS/2/C18/C1857/E=
1362.Gif

If anything goes wrong with these parts, you have to go into the
transmission.

If the 550 cotter breaks or falls out, the 92042 pin won't follow the
groove in the shifter drum. I can't imagine *why* Kawasaki designed
the shifter fork like this.

If the 92009 screw loosens up, the shifter mechanism can't rotate the
shifter drum. The screw holds holds the 13091 pin retainer onto shift
drum and there are several little steel pins that will fall out.