96 VN800 2nd gear lurch - Kawasaki Vulcan Forum : Vulcan Forums
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post #1 of 3 (permalink) Old 08-27-2019, 10:36 AM Thread Starter
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96 VN800 2nd gear lurch

Hi All,

Buddy got a 1996 VN800 on a deal. Bike is sputtering/lurching in second gear.

We rebuilt Carb, Chain didn't appear to be binding, Checked the throttle cables, replaced vac lines.

Buddy took it to motorcycle shop who said it's transmission.

Have a line on a used transmission that looks good for $80.

That being said, I can't find a good list of gaskets I'll need and not a lot of step by step pictured instructions.

My factory service manual for my honda magna appeas to be a bit more complete than the Kawasaki FSM for his bike. Also on my magna I can remove a side cover to replace transmission gears.

Has a member here done a good write up of a transmission replacement? If so can you point me in the right direction?

Do I really need to split the case to fix this?

(Forgive this one, been a couple weeks since I read the Kawa manual) I can keep the cylinder heads on just fine doing the tranny replacement. Yes?

Tips for splitting the case that are not listed in the FSM?
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post #2 of 3 (permalink) Old 09-07-2019, 04:08 PM
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Sounds like you need a Haynes manual.
I've got a '96 VN800 Classic. Being as old as she is she needs a lot of love. Bought the one on the link posted. Gotten me through everything. Haven't done any tranny work on mine, though. But if I needed too this is what I'd use

Haynes 2457 Technical Repair Manual https://www.amazon.com/dp/B000GTQ662..._WVbDDbCS1XP88
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post #3 of 3 (permalink) Old 09-07-2019, 04:10 PM
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Try BikeBandit for your gaskets. They use same diagrams as Haynes manual to list part numbers
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