Gear shifter loose

[DailyRider]

OK, I'm in a bit of a pickle and need some quick help. I rode down to work and was at a stop. I was unsure of which gear I was in so hit the shifter a couple of times and the lever has popped loose. Going to look at it after work and hopefully get home. Wondering if anyone has any idea about that mechanism and if it is likely loose and needs an adjustment or did something give way?

[jre258 in SoDak]

The gearshift lever connects to the transmission through an adjustable linkage. Maybe a pin fell out or the linkage unscrewed itself somehow.

[DailyRider]

OK, thanks. Seems like that may be the case. I appreciate the feedback.

[doug of so fla]

Sometimes the little linkage ball & socket (that no one ever lubes) gets broke especially when one "STAB" shifts. Sitting at a light in neutral and forgeting to go when light turns green then panic "stab" shifts into first, usually using to much force in this sitiuation. Best way for me on a XII is to sit with clutch in low and then you can just go. The wider clutch levers make it more comfortable to hold the clutch in but with Kaw's easy find neutral / with lite we get in the habit of putting it in "N" & forgeting to shift & go. That is very hard on transmission and linkage.. Good winter project is to grease clutch and brake linkage especially the pivot bushing and pivot bolt on clutch lever. Along with shift linkage & all cables. All easy to do and makes it easier to RIDE SAFE!!

[Bill O]

OK, I'm in a bit of a pickle and need some quick help. I rode down to work and was at a stop. I was unsure of which gear I was in so hit the shifter a couple of times and the lever has popped loose. Going to look at it after work and hopefully get home. Wondering if anyone has any idea about that mechanism and if it is likely loose and needs an adjustment or did something give way?

Most likely, one of the "Bell" connectors between the foot shifter and the transmission linkage has broke loose. This is a common failure. Many Voyager riders carry an extra shifter linkage with them in their parts kits.

The linkage can be braised or welded back together to repair the linkage. I believe there is an article in the tech section about this problem.

Bill O

[DailyRider]

Thanks everyone. Good to know about carrying an extra linkage. Well, good news. I changed back out of my suite at lunch and got down on the ground to inspect a little closer. Fortunately for me, it was just a loose screw on the shift lever itself. I've not ridden it, but I tightened it and it seemed to fix the problem. Thanks again. Just had the bike a few weeks and ride 90 miles round trip to work. I'm going to go over the bike with a fine tooth comb this weekend and check for loose connections.

[Bill O]

For those who don't know what part I referenced, here is a link to a shifter linkage on Ebay.

http://www.ebay.com/itm/1989-Kawasaki-V ... 0b&vxp=mtr

This is what I carry in the bike for emergencies.

I have had two of these break on my over the years. Both were repaired by brassing or welding the pins back on the levers.

Bill O

[Bill O]

For those who don't know what part I referenced, here is a link to a shifter linkage on Ebay.

http://www.ebay.com/itm/1989-Kawasaki-V ... 0b&vxp=mtr

This is what I carry in the bike for emergencies.

I have had two of these break on my over the years. Both were repaired by brassing or welding the pins back on the levers.

Bill O

It was brought to my attention that the link provided states the item is a rear brake linkage. This is obviously mislabeled and is, in fact, the shifter linkage... Trust me!

Bill O

[DailyRider]

Thanks Bill O, great tip.

[RoadSailor]

Hey Folks,
I had my shifter linkage shear off at one of the ball joints while on a tour in the middle of rural Pennsylvania last summer. To my great good fortune, a kind older gent threw me the keys to his pickup so that I could drive 45 minutes down the road to the nearest Kawasaki dealer to try to find a replacement part...
The dealer had no stock parts for my Voyager XII, HOWEVER, I ended up spying a similar linkage on a newer 2013 Vulcan V-twin sitting in the showroom.
To my second good fortune, I was able to buy the part off of the showroom bike.
As it turned out, one of the linkage shafts was slightly longer than the stock linkage, causing the outer ball joint to project out beyond the transmission cover plate so I had to leave the cover plate off - but the linkage worked! We were back on the road!
I have since ground a little hollow in the transmission cover plate to allow for the new (Vulcan) linkage and have since refrained from doing any "stab" shifting. (I agree with Doug - This was definitely the cause of my linkage failure).

Keep this "Frankenstein" solution in mind if you are having trouble finding a replacement linkage.

Tom
Waterloo, Ontario

[Lucasind]

...Thanks for making that post Tom, who would have guessed the shift linkage from very different bikes would be remotely compatible,,,,,obviously a savings for manufacturing costs,but alot of old XII's still going long distances and anything can happen...and far away from home is when it hurts
the most ! .....................tony

[Bill O]

Hey Folks,
I had my shifter linkage shear off at one of the ball joints while on a tour in the middle of rural Pennsylvania last summer. ...............

Tom
Waterloo, Ontario

Tom,
This has happened twice to me. (Two different Voyagers) The first I had braised back on the lever, and it has never failed in the last ten years. The second one on my '03, but I was a block from home. Made it home in 1st gear and I removed and MIG welded the bell back on this one. Still working. The shifter linkage is one of the extra items I carry in my bike repair kit. (Easy to replace out on the road.)

Bill O