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Old 11-05-2013, 10:27 AM   #1
MiteyF OP
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Joined: Jul 2010
Location: Michigan... temporarily
Oddometer: 1,846
Shifter on re-assembled Kawi smoker VERY loose

So I'm working on a long-term street tracker 1971 Kawasaki F8... I recently found the time to get the clutch and bits back onto the engine, but when I did, I noticed that when the shifter is moved, there is a LOT of play, with almost NO resistance when trying to shift between the gears. It WILL shift into gear however. I'm sure I got something in there wrong, although all parts seem to be accounted for, and according to the fiche online, everything looks right. I didn't split the case, so it's not THAT deep, and the bike was never running before I got it (about 2 years ago) so I couldn't tell ya what the shifter felt like before it was disassembled... this is why I like to keep on my projects until they're done, to avoid shit like this.

I can snap a pic later, but does anyone have any idea what might be the cause? Maybe someone has run into this before and can have an "ah-ha" moment for me?

I don't want to button up the clutch cover with the new gasket until I figure this out.

EDIT: If I watch the shifter fork (right term?) moving the shift drum when I move the shifter, there's a lot of slop between when the fork hits the pegs on the drum... sooooo...?
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Old 11-05-2013, 08:40 PM   #2
Kai Ju
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Location: So Cal
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Sounds like the shifter pawl return spring is either missing or not properly installed, based on you description of it shifting yet not having a lot of resistance. Not to mention the excess play noticed in the shift mechanism.
A pic certainly would help, especially since I'm not familiar with that model.
The basics are probably the same to other bikes since there is only so many ways you can turn a shift drum.
Most of the resistance you feel is the return spring.
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Old 11-06-2013, 11:45 AM   #3
kbasa
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Joined: May 2002
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Moved to 2 smokers.
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