Kawasaki Voyager ZG1200 '94 Having issues shifting gears

[Sasha Al]

Today I developed an oil leak on the left side of the engine. I started the bike, put it on the stand, and shifted to the first gear. I ran the bike on idle speed for 30 minutes (with the wheel spinning) to see where the leak was coming from. After the 30 minutes I noticed an oil leak coming from under the Clutch Slave Cylinder.

The Push Rod oil seal was bad. I replace the oil seal, placed push rod back into place (correct side out), placed Slave Cylinder back, put the rest of the bike back together and started the bike. The bike was running fine, but when I tried switching gears, it didn't switch. After jerking lever multiple times, it would switch sporadically throughout all gears. Sometimes I would have to jerk the lever 50 times to get it back into neutral.

Once it is in gear, when I depress clutch lever it works fine and disengages (you can see the rear tire stop / start spinning). I also bled the Slave Clutch just in case.

I'm not sure if it matters, but when I first pulled the push rod, the bike was off and in first gear.

We noticed on the inner end of the push rod it looks like a tiny circular in graved mark from what looks like a ball bearing. We also flashed a light directly into the push rod receiver, saw no ball bearing, but saw a similar in graved mark on the receiving end.

We tried researching if there even is a push rod ball bearing, but were unable to find anything. Went through the bike manual, and couldn't find anything either.

[voyager55]

https://onedrive.live.com/?cid=25F882B6 ... D0CA8D!173" onclick="window.open(this.href);return false;

Chapter 5 might help

[triton28]

Please note that when I open Chapter 5 from the link it is NOT a ZG1200 clutch.

[voyager55]

?? Says clutch when I open it.

[triton28]

With all due respect to the nomenclature used, I say again, it is not a chapter for the ZG1200 clutch; see illustrations on 5-3, 5-12, 5-13, 5-14.
There is no electric start chain on the ZG1200 clutch hub side of the transmission, and even the outer cover is wrong. I would just like for all to be aware of this error, that's all.
Dave

[voyager55]

That's the only factory service manual made for the 1200 voyager

[doug of so fla]

Triton 28 is correct!! the clutch 5-2 is not for a XII, Someone somehow downloaded something other than a XII clutch diagram, other pages for the downloaded manual look correct. My manual is correct with the proper XII clutch info in it. Does not match the one in the link. Did not check all the other pages but the ones I did looked ok ?? Be carful using that download link it could make you crazzzzzy!!! Good catch triton may have saved someone a bad headaKKKKY!!..

[triton28]

Just tryin' to spare anyone problems, that's all.
Dave

[Mr Jensee]

Folks, I apologize, I have NOT a clue how the chapter 5 got switched for a ZRX1100 engine got in there. I am working on a rescan of the manual and will post it as soon as I can. I have a lot going on now, my wife's mom (living with us) died unexpectedly last week and now my mother is in the hospital 400 miles away with a brain bleed not looking good. I just got back tonight and read this and double checked and it is indeed wrong. Let me know if anything else looks suspicious as well. Bear with me.

Ok, fortunately I had another copy of the manual on PDF. The correct chapter 5 is now there. Click on my link to take you to it. Thank you for being patient and remaining as confused as I was!

[voyager55]

Prayers sent to all the families. I hope your Mom inproves quickly.

[Sasha Al]

Hi thanks everybody for help. Today I found a problem. It was external shifting mechanism spring, the spring that located between Neutral positioning lever and Gear positioning lever.


Now I just need to order new gasket and slave cylinder spacer and put everything together.

[Mr Jensee]

Prayers sent to all the families. I hope your Mom inproves quickly.

Thank you. Lots of prayers have come our way. She seems to be improving today, alert for the most part and finally eating and drinking. She just may pull through this one!