Transmission Repair - 2nd Gear Problem.

[ppgflyer]

Following up on my previous post http://vulcanbagger.com/forums/showthread.php?t=35282 I have more information for those having the same issue, or are merely interested in seeing what a complete tear-down, service and re-assembly involves.

I have posted some more pictures on my photobucket page which can be seen here :- http://s1198.photobucket.com/user/ppggreg/library/ and there will be more soon as I will be assembling the bottom end this weekend. The top end is on hold for gaskets.

The biggest obstacle I had to overcome was finding the transmission parts. To replace all the gears damaged plus the shift fork it was going to cost over $400, the gears were running about $90 each. The output shaft 5th gear, the one with two sets of dogs that locks 2nd or 3rd gear was out of stock everywhere I called. To add insult to injury it is discontinued and no longer in production

So I tried to see what parts replaced or superseded my part. NOTHING Okay, Kawasaki Tech line will surely be able to provide the answer the support specialist said "NOPE, no replacement, equivalent or alternative" well this is for you Kawasaki Thanks for your lack of commitment to support your customers.

So what did I do I can hear you asking, did you look for a used 2001 VN1500-L2 transmission? Sure did, Ebay, Craigslist, wrecking yard put it out on their nationwide hotline - A big fat ZERO. But wait, a vendor on Ebay had a used transmission for a 2005 VN1500 Classic, pictures looked the same. Gear teeth and ratio's matched but not a single part number matched, so after some I decided that Kawasaki wouldn't completely change the VN1500 transmission, in fact I doubted they would change anything other than part numbers.
So I made a leap of faith and purchased the used transmission for $253+shpg,

I'm happy to report that the transmission turned out to be exactly the same as my original and I will be able to completely replace the whole thing for less than the price of three new gears. More importantly, the parts for a 2005 VN1500 Classic, and Nomad for that matter will not only fit the 2001 Nomad but as far as I know ALL those parts are still in production and still available

I can't believe Kawasaki has not produced a cross reference publication that identifies current parts that fit where previous parts are discontinued.
Some information is available for some parts that are superseded but in this case it seems to be lacking.

I hope this info helps those that take their 2001 Kawi to the dealer and he tells you the part is not in stock and no longer in production.

Greg.
PS: my apologies for the excessive length of this post.

[manban9888]

Great info. Thanks for sharing

[ringadingh]

Good info, I had 4th gear start skipping on me last year, I decided to buy and install a whole complete new motor, mine had almost 90k on it so I wanted something with low miles. Installed a 06 1600 with about 17k on it. I figured it was a good move for me, it took about twelve hours to re & re and cost me $1200.00

[blowndodge]

Upgrading only cost me 24k but worth it!!

[dank]

Originally Posted by blowndodge

Upgrading only cost me 24k but worth it!!

Only cost me 15K, and mine is smoother, faster, and corners better...though apparently you think yours smells better. I wouldn't know.

[pbab]

Originally Posted by dank

only cost me 15k, and mine is smoother, faster, and corners better...though apparently you think yours smells better. I wouldn't know.

lol!

[ppgflyer]

Pictures of final assembly of my VN1500-L2 bottom end are now up on my photobucket page for those that are following the saga http://s1198.photobucket.com/user/ppggreg/library/

Everything went fairly smoothly, torquing some of the nuts can be a bit challenging as so much force is required to achieve the specs, but it is achievable. Bear in mind that I am doing this solo and have nobody to assist.

The engine is getting quite heavy at this point an having a hydraulic lift table is very useful.

I did some further investigation on 5th gear. It looks like the latest part for a 2008 VN1600 Classic or Nomad (13262-1070) will fit the 2001 Nomad so hopefully that part will at least be available until 2018.

If you have any questions please feel free to email or PM me.

I hope this information and the pictures posted on photobucket help any members of VB to answer any questions they might have about servicing their machines.

I will post the top end rebuild next week, after I have the necessary gaskets.

Greg.

[Dave]

Sure wish I had the talent and knowledge to do something like that. Hell, I take my bike to the shop for oil changes.

[ppgflyer]

Well Dave, after servicing my front forks and rear shocks I wasn't about to spend $1500 to $2000 for a replacement engine when I could fix the transmission for $500 in new parts. So far it's cost me $300 for a used transmission and $100 in gaskets.

Having most of the tools and access to a machine shop has allowed me to do this, I only have a car port at my house so there is no way I would try it there but changing your own oil is easier on a motorcycle than it is on a car, and when it comes to replacing your clutch plates that's about as easy as changing your own brake pads.

[davidhollinger]

Is there a write up on here or Gadget's site on changing the clutch plates/Spring?

[MAS Tequila]

Originally Posted by davidhollinger

Is there a write up on here or Gadget's site on changing the clutch plates/Spring?

http://www.gadgetjq.com/clutch_spring_replacement.htm

MT

[clayton]

Very Nice job.
PIC's are great.

[Lee Nedirof]

Sometimes the original transmission fitted in various bikes can be changed with another transmission of proportionate figures. Another option to try for is transmission repair, which can make your vehicle's transmission operate smoothly.