Question about 2000 kawasaki VN 1500 Vulcan Classic Tourer Fi

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Kawasaki vn1500 classic 1st gear problem!..

My 1996 kawasaki vn1500 classic jumps in 1st gear when pulling away but is ok in all other gears..i've replaced all friction plates and torque limiter springs but this as not sorted the problem,i would be grateful for any advise on what the problem may be or known faults..thanks paul..

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It sounds like you have a broken dog on 1st gear. (on sprocket inside gear box) gearbox needs stripping down and investigating.

Posted on Feb 21, 2009

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TO ALL VN1500 OWNERS....This once happen to me,
I went to the garage to start the bike "Nothing ""The first thing is the lights are bright but no turning over,Next you think the solenoid is kaput but the answer was very simple and the fix takes 30 seconds..
Do not take the bike to bits looking for other problems and look at the clutch leaver and you will see some wires going into a plastic shroud going into the switch in the clutch leaver, Make sure this has not popped out if its connection as it some times may do after a few years due to constant turning on the handlebars,
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1 Answer

Kawasaki vn1500 2nd gear jumping out


Hi, make sure your lever is adjusted to your foot. You can turn the linkage arm adjuster up or down to get a better throw on the lever. If you don't wear boots when riding, this is always a problem on a Kawasaki due to the positive neutral finder. The fist question you get when you call the Kawasaki Hotline is if the rider wears boots or not.
If adjusting the lever doesn't help the problem is internal. Under the gear change cover the items to check would be the pawl that rotates the drum and the detent arm and spring. If the edge of the pawl is worn, it won't move the drum far enough. If the detent arm or spring isn't working, it will want to drop into a false neutral. I've had very good luck by removing all of the parts and polishing them, removing any burrs and replacing the springs. If the problem isn't found under the cover in the gear change area then the only other solution is to pull the motor apart and inspect the tranny itself.

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CORRECT. COMPLETE ENGINE DISASSEMBLY BECAUSE CRANKCASES SPLIT HORIZONTALLY CYLINDER'S MUST COME OFF FIRST. BIG BUCKS

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Hi Buddy
There is not an easy solution to your gearbox problem,it is general wear on the 'dogs' or 'shift drum'..The only other thing it could be is wear on the 'external shift mechanism'.
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Keeps jumping out of second gear. Tore down the


The gears ARE probably fine. The problem is a slightly bent shift fork. Since the engine is apart I would STRONGLY advise you replace the shift fork. If nothing else it is cheap insurance that you won't have to replace it four weeks later because it won't shift into first. I have replaced shift forks that looked perfectly good but were bent such the you couldn't get into 2nd gear. Looks can be deceiving.

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