Question about 2004 kawasaki VN 1500 Vulcan Classic

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Clutch wont disengage

I have a 1991 Kawasaki Vulcan 1500 and the clutch will not disengage, stays in gear even when you pull in the clutch

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  • Anonymous Mar 20, 2014

    Clutch not disengaging completely

  • Williem Vell Jun 04, 2014

    disks may be in the wrong order or clutch cylinder may need bleeding

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  • kawasaki Master
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Wet clutches need the proper oil. Is there any possibility it has the wrong oil?

Posted on Jun 19, 2009

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1 Answer

2000 Kawasaki VN 1500 Vulcan Classic clutch will not engage


Hi, Anonymous and the usual suspects are:
1. Clutch cable adjusted too tight.
2. Pressure plate center screw adjusted too tight
3. A broken clutch rod.
4. Slave cylinder piston stuck.
5. Clutch plate missing from the clutch pack.
6. Clutch plates have worn past minimum specifications.
7. Clutch plates crystallized due to incompatible oil.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
http://www.kawasakimotorcycle.org/forum/kawasaki-cruisers/66113-gears-wont-engage.html
clutch will not engage
Kawasaki VN1500 Service Manual
OEM Parts for Kawasaki
2004 Kawasaki Vulcan 2000 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Nov 15, 2017 | 2000 kawasaki VN 1500 Vulcan Classic

1 Answer

My 2004 1500 Vulcan Nomad will not stay in gear 2nd thru 4th gears? It started off as a momentary thing where when I went from 1st to 2nd it would go into a false neutral. now it won't stay in gear at all...


Always start with the easy (read cheap) stuff first. Make sure that the clutch is fully disengaging when in gear and engine running. If bike 'clunks' and lurches forward as soon as you shift into any gear, it may simply be that your clutch needs to be bled and/or adjusted so that you are fully engaging/disengaging the gear. More likely, however, the shift lever was subjected to a heavy foot resulting in the shift fork being bent. This prevents full engagement of the gear resulting in it popping out under load. Unfortunately, this repair requires a teardown. Continued operation with the tranny popping out of gear will round off the shift dogs and create an even more very expensive repair.

Mar 05, 2014 | 2004 kawasaki VN 1500 Vulcan Classic...

1 Answer

2004 Kawasaki VN 1500 Vulcan Classic dies when put into gear


Hi, Anonymous and the usual suspects are:
1. Faulty wiring to any safety switch.
2. Safety switches loose at the mounting point.
3. Faulty kickstand safety switch.
4. Failed kickstand safety switch circuit diode.
5. Stretched side stand spring.
6. Side stand not coming up far enough to disengage switch.
7. Faulty clutch lever safety switch.
8. Faulty neutral safety switch.
9. Clutch not properly adjusted.
10. Clutch plates sticking, forward lurch
For more information about your question and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Stalls when putting in gear Kawasaki Vulcan Forum Vulcan Forums
Stalls when putting into gear first time
Kawasaki VN1500 Service Manual
OEM Parts for Kawasaki
2003 Kawasaki Vulcan 1500 Classic Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Nov 15, 2013 | 2004 kawasaki VN 1500 Vulcan Classic

1 Answer

2003 Kawasaki Vulcan 1500 Nomad sticking clutch plates


Hi, Anonymous if your bike has been sitting for weeks or months and you get it started, put it in 1st gear, it lurches forward and stalls. Your clutch has bonded from surface rust on the steel plates due to condensation from running hot and shutting down in a cool environment. The easiest way to remedy this situation is to push start the bike in gear, shift and drive it normally until it reaches operating temperature and you will be fine. In severe cases, the clutch will have to be removed and disassembled, the clutch plates decontaminated and reassembled and installed.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Clutch is stuck Vulcan Bagger Forums
Jerk when shifting into first gear
Kawasaki VN1500 Service Manual
OEM Parts for Kawasaki
2003 Kawasaki Vulcan 1500 Classic Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

May 19, 2013 | 2004 kawasaki Vulcan 1500 Nomad

1 Answer

2007 Kawasaki Vulcan 900 Custom dies when put into gear


Hi, Anonymous and the usual suspects are:
1. Faulty wiring to any safety switch.
2. Safety switches loose at the mounting point.
3. Faulty kickstand safety switch.
4. Failed kickstand safety switch circuit diode.
5. Stretched side stand spring.
6. Side stand not coming up far enough to disengage switch.
7. Faulty clutch lever safety switch.
8. Faulty neutral safety switch.
9. Clutch not properly adjusted.
10. Clutch plates sticking, forward lurch
For more information about your question and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Stalls when putting in gear Kawasaki Vulcan Forum Vulcan Forums
Stalls when putting into gear first time
Kawasaki VN900 Custom Service Manual
OEM Parts for Kawasaki
2007 Kawasaki Vulcan 900 Classic Owner Manual

Apr 13, 2013 | 2007 kawasaki Vulcan 900 Custom

1 Answer

2001 Kawasaki EN 500 Vulcan Classic the clutch will not disengage


Hi, Duane and the usual suspects are:
1. Clutch not properly adjusted.
2. Clutch plates rusted together.
3. Hydraulic clutch needs bleeding.
4. Faulty clutch slave cylinder.
5. Faulty clutch ramp mechanism.
6. Broken clutch rod
7. Clutch pack loose on the main shaft.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Clutch wont disengage fully Kawasaki Vulcan Forum Vulcan Forums
http://www.kawasakimotorcycle.org/forum/kawasaki-cruisers/145913-clutch-wont-fully-disengage-vulcan-vn1500-classic.html
Kawasaki EN500 Vulcan 500 LTD Service Manual
OEM Parts for Kawasaki
http://mybikemanuals.com/kawasaki

Mar 23, 2013 | 2001 kawasaki EN 500 Vulcan Classic

1 Answer

2007 Kawasaki Vulcan 1500 Classic dies when put into gear


Hi, Allen and the usual suspects are:
1. Faulty wiring to any safety switch.
2. Safety switches loose at the mounting point.
3. Faulty kickstand safety switch.
4. Failed kickstand safety switch circuit diode.
5. Stretched side stand spring.
6. Side stand not coming up far enough to disengage switch.
7. Faulty clutch lever safety switch.
8. Faulty neutral safety switch.
9. Clutch not properly adjusted.
10. Clutch plates sticking, forward lurch
For more information about your question and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Stalls when putting in gear Kawasaki Vulcan Forum Vulcan Forums
Bike shuts off when putting into gear Kawasaki Vulcan Forum Vulcan Forums
Kawasaki VN1500 Service Manual
OEM Parts for Kawasaki
2007 Kawasaki Vulcan 1500 Classic Owner Manual

Mar 16, 2013 | 2007 kawasaki Vulcan 1500 Classic

1 Answer

2002 Kawasaki VN 1500 Vulcan Drifter kickstand down in neutral dies when clutch released


Hi, Anonymous the ignition circuit cut-off system comprising of the side stand switch, clutch switch and neutral switch has the following functions:
a. It prevents starting when the transmission is in gear and the side stand is up, but the clutch lever is not pulled.
b. It prevents starting when the transmission is in gear and the clutch lever is pulled, but the side stand is still down.
c. It cuts the running engine when the transmission is in gear and the side stand is moved down.
Periodically check the operation of the ignition circuit cut-off system according to the following tests.
With the engine turned off:
1. Move the side stand down.
2. Make sure that the engine stop switch is set to "RUN"
3. Turn the key to "ON".
4. Shift the transmission into the neutral position.
5. Push the start switch if the engine does not start the neutral switch may be faulty.
With the engine still running:
6. Move the side stand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the side stand down if the engine does not stall you may have a faulty side stand switch.
After the engine has stalled:
10. Move the side stand up.
11. Keep the clutch lever pulled.
12. Push the start switch if the engine does not start you may have a faulty clutch switch.
This check is most reliable if performed with a warmed-up engine.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Shuts down when clutch is released KawiForums Kawasaki Motorcycle Forums
won stay on in neutral with kickstand down Kawasaki Vulcan Forum Vulcan...
Kawasaki Vulcan 1500 Drifter Service Manual
OEM Parts for Kawasaki
2002 Kawasaki Vulcan 1500 Drifter Owner Manual

Feb 26, 2013 | 2002 kawasaki VN 1500 Vulcan Drifter

1 Answer

1996 Kawasaki VN 800 A Vulcan clutch won't disengage


Hi, Anonymous and the usual suspects are:
1. Clutch not properly adjusted.
2. Clutch plates rusted together.
3. Hydraulic clutch needs bleeding.
4. Faulty clutch slave cylinder.
5. Faulty clutch ramp mechanism.
6. Broken clutch rod
7. Clutch pack loose on the main shaft.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Clutch won disengage fully Kawasaki Vulcan Forum Vulcan Forums
http://www.kawasakimotorcycle.org/forum/kawasaki-cruisers/145913-clutch-wont-fully-disengage-vulcan-vn1500-classic.html
KAWASAKI VN800 Service Manual
OEM Parts for Kawasaki
Kawasaki VN800 Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Feb 21, 2013 | 1996 kawasaki VN 800 A Vulcan

1 Answer

2002 Kawasaki VN 1500 Vulcan Classic clutch will not disengage


Hi, Anonymous and the usual suspects are:
1. Clutch not properly adjusted.
2. Clutch plates rusted together.
3. Hydraulic clutch needs bleeding.
4. Faulty clutch slave cylinder.
5. Faulty clutch ramp mechanism.
6. Broken clutch rod
7. Clutch pack loose on the main shaft.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Clutch won disengage fully Kawasaki Vulcan Forum Vulcan Forums
Clutch wont disengage Vulcan Bagger Forums
Kawasaki Vulcan 1500 Classic Fi Service Manual
OEM Parts for Kawasaki
2002 Kawasaki Vulcan 1500 Classic Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Jul 22, 2012 | 2002 kawasaki VN 1500 Vulcan Classic

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