If not, the rear wheel can lock and skid, causing loss of control!! The slip prevents the rear tire from locking up on a downshift possibly causing a mishap. Doing the project with the bike on the sidestand means you don't have to drain the oil. Note the orientation of the washers: They are in this order: engine then the clutch spring. The Project If you do this 'by the book' you'll be removing the speedometer assembly, the gas tank and a whole bunch of unnecessary stuff. I guess i might as well replace them while i have the bike apart. Good luck and have a wonderful day.
You'll only need it a minute or two. The heat shield assembly should come free fairly easily. Unscrew brake switch holder from brake switch being careful to turn the holder, not the switch you could break the wire off. Clutch plates crystallized due to incompatible oil. Before you start removing these make a template using your replacement gasket so you can keep track of where each bolt goes.
Hope this helps and thank you for using FixYa! As it happens, Judge has also engineered some special washers designed to protect the clutch spring from wear for many tens of thousands of miles while firming up the clutch action at the same time. If you only have a breaker bar. One is just very slightly larger than the other so it can slide over the 'step' on the clutch spring carrier. Look closely below the clutch basket and you'll see a large dark hole. Don't force anything or you could bend the lower portion where it slides into the lower heat shield.
If you're doing this on the sidestand you won't lose any oil An impact wrench is strongly recommended to remove the 27 mm clutch spring nut. A couple of hits with the impact wrench and a 27 mm socket and the nut zips right off. Technically 108 foot pounds of pain in the butt unless you have an impact wrench. This procedure I just finished my Nomad so it's all fresh in the noggin will get you through the task in two to three hours. Help out your fellow V2K riders and maybe they can help you too! Remove 2- 13mm engine mount bracket bolts from right side downtube. . If there's no way to borrow or rent an impact wrench then you'll want to check for his technique for muscling the clutch spring nut off.
I know i have a lot more reading to do but most of the information i have found on the internet only talks about judges washers and the 2002 mean streak spring plate. This is really a simple project requiring only basic hand tools though, as you'll see a compressor and air wrench can be pretty handy. Shift mechanism arm is broken. If you have a compressor you're home free. You won't lose a drop, trust me. Remove the clutch push rod and set aside preferably showing the order you've taken everything apart and now you're looking at. Any other problems with the clutch system should be handled according to theshop manual.
The heat shield assembly should come free fairly easily. Clutch Parts for Spring Replacement All Vulcan 1500 and 1600's now share the same clutch parts. If you have stock exhaust, note the pipe heat shield is held in place by three hose clamps with 10 mm bolts. I traded my Suzuki in June of 2008 for a '08 Kawasaki Vulcan 2000 Classic and found the forum with the same kinds of helpful people. It will help if you reach down inside the lower frame tube and unclip the brake hose.
The washer will carry the load and the wear. Do not take the bike to bits looking for other problems and look at the clutch leaver and you will see some wires going into a plastic shroud going into the switch in the clutch leaver, Make sure this has not popped out if its connection as it some times may do after a few years due to constant turning on the handlebars, When this is not connected you will have a bike that will not fire up but comes alive and you will hear a clicking noise but this is from the engine carb area and every function of the bike will work but it will not turn over, Worth looking at and saves sixteen quid for a starter unit you never needed. Just loosen those bolts and slide the clamps 'up' toward the front of the bike. The orientation of the parts is not really obvious by looking at the parts themselves but according to the parts fiche, the new piece: the 'crown washer' fits flat side against the spring side of the holder flange with the 'crown' points facing towards the spring the crown points fit into the grooves on the spring. Look closely below the clutch basket and you'll see a large dark hole. Well then, it may be time for a new spring so lets get started. This allowed the clutch spring to over-flex resulting in premature failure.
Put it back on the starter so you don't forget it. This assembly will increase rear wheel traction! There are many sizes and you don't want to get them mixed up. Posted on Jul 04, 2011 Hi, Randy and the usual suspects are: 1. You will also see I used a MeanStreak spring slightly thicker than the stock Nomad spring and a set of Judge's washers explanation later which should not only keep this spring going strong for a long long time but also gives a more positive clutch action. Just loosen those bolts and slide the clamps 'up' toward the front of the bike. It must be able to melt away as the oil heats up! If necessary, transport your bike to the dealer or shop and have a professional technician take it for a test drive, if it is in running condition, and give you a written estimate of repairs and answer any specific questions you may have about your problem. If that sounds like you take a look at this.