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Unfortunately yes you have to disassemble the engine to fix the transmission on this bike. New parts are not available and you’re going to need to find the correct engine gasket kit. The ‘96 is a 4 speed transmission. All after ‘98 are a five speed except the Vulcan 88( 4 speed up to 1999). Message me if you have more questions

I’ve heard there’s a factory authorized repair on these. Involves new valves and head work and they added a coolant line to the carburetor. You can have your vin checked at a local dealership. If it’s never been touched it could qualify for the dealership to do the work and provide the parts. Mine has had previous head work and doesn’t qualify. Going to replace the factory air filter assembly. Hopefully this helps cool the carburetor. The carburetor is tucked in so far between the heads. My theory is it’s too hot and causes the hiccups and backfiring under load at low rpm

I finally found a set of new/used upper manifolds. Also need to change the main jet and jet needle jet height. Stay tuned for a new video coming soon

@@750UT I’m about to replace the upper carburetor boots and rebuild the carburetors once again. I finally found a set of used ones that are in really good condition. Stay tuned for more videos coming soon

@@a.b1266 they are fun to ride and reliable but parts can be hard to find.

@@miriamfitch4483 working hard on it but it’s so HOT in the garage

@@duanetrivett750 they were a fun project. Picked up a’67 in a custom frame and a’63 with a’66 engine installed. Got them both running and sold them

I’m learning the hard way. Blood sweat and tears.

@@sigmalawpenske this is not a how to channel. Just documenting projects for customers and for my future reference

@@sigmalawpenske if you need help or advise just ask a question.

@@sigmalawpenske watch all of my videos and you will most likely find what you are looking for. If you have a specific question I’m willing to answer it. Thanks for visiting my channel

Yes I made an update video on this. Clutch cover was warped and had to be replaced

@@Sigurd651 it is cheap but easy and cheap to repair. Perfect for teaching children how to ride

No they don’t. They are pressed together and the metal edge on the slide is rolled over. If you cut them you can’t put a new one on. I had to find a used set

@@peterrose7329 good luck with that method. Something is wrong and can lead to more damage or possibly locking up the engine while riding

Parts are cheap on Amazon and they are fairly simple to work on

This might work for a good set. Mine are already damaged and can’t be done that way. The good news is I have located a very good set of used ones. Will post a new video when I do the install

@@thomascyganiak5946 ended up having to redo this project. The new seals failed and had to buy new ones. Check my page for the update

‘96 Fxdwg fork seals and bushings

@@hoytskyrme5315 tattoo is what it is and only those that know understand

@@fitchpaintingrepairllc9871 I have 2 dots. I got one of these TL ‘s was a piece when I got slowly rebuilding

@@anthonymatteson9499 might need the carburetor cleaned. Sounds like jets are clogged or the diaphragm for the slide is damaged. Does it run rough or cough spit or pop while trying to accelerate?

@@fitchpaintingrepairllc9871 i just had it professionally cleaned last week as I thought that was the issue, it runs fine with no air filter on but then when I put one on it idles great but accelerating issues happen and spits and sputters and back fires and when I shut it off after it get nice and warm a flame shoots out the exhaust

@@anthonymatteson9499 sounds like it is running very rich. Does it have a smell of gas or is fuel dripping from the breather? Empty the fuel tank and check for contamination like water or rust. The float level could be set incorrectly. Professionally done doesn’t necessarily mean it was done correctly or there could be another issue

Electric gremlins are by far the hardest thing to diagnose. Don’t forget to check the fuses and the ground to the coils. It cranks but no start with no spark at the plugs? Check that the battery has at least 12.7 vdc. Good luck

@@fitchpaintingrepairllc9871 I figured it out bad connection with the old white factory plug. Cut it all out one by one and put a new 16 pin connector to hopefully stop any future problems with that plug fingers crossed.

@@unknownamigo0 lots of movement with the way the wires are installed on that bike. Leave some slack and use dialectic grease

I did find a set of used ones that are in good condition. Haven’t installed them yet

The 86 is much bigger diameter and length

Sounds like you got things under control. Performance machines often require lots of maintenance. Good luck with your ride and hope you have many more miles and smiles

@@fitchpaintingrepairllc9871 haha yeah I've been researching the hell out of things. It's old, I want to know how to improve it.

It is not the pulley. It was the rubber engine mounts. The rear stabilizer was completely torn and the front was going bad as well

Thanks

Stock seat off of a late 90’s Suzuki murauder seat. Slightly modified on the bottom to fit the frame rails and added a clamp to mount it to the cross rail under the back of the seat

If it works for you then do it. What you seem to have missed is the boots are damaged and can’t be manipulated that way or more damage will happen. If you are able to find these upper boots to replace them I would gladly try your method. Used ones are hard to find and new ones are unavailable. And yes this is my personal bike I’ve been working on since it was new. The motor has been off the frame many times. First time after running over a pedestrian and totaling the bike. Thanks for your comment and info on your experience with the VT700c shadow. Many more miles and smiles

@@fitchpaintingrepairllc9871 I have even used that method on split boots, too. You crack it worse because it is cold. The heat takes that risk away. The heat excites the rubber molecules and allows them to move more without losing cohesion. I have probably 5 extra upper boots and so I wasn't afraid to experiment to find the best way. Including when the boot is damaged. I have both professional and personal experience working on bikes and quads.

@@Tinkerbell227 still haven’t solved my problem but thanks for your advice. What works for one project doesn’t necessarily work on another. I’m not telling anyone how to do anything. Or trying to prove how much experience I have. Provide positive feedback or info or move along. If you have so many extra parts than I guess you have room to make mistakes. Donations are welcome

@@fitchpaintingrepairllc9871 My business is to small for donations. $50 a boot plus shipping. Shelton's Odd Jobs & Oddities LLC.

Going to mount a sidecar to it after I change the oil and full service. Horn and fuel gauge are not working but I’ll sort that out soon. Stay tuned for more of the project

TH-cam @Fitchpaintingrepairllc

Still sorting out this issue with the bike. I found a factory authorized repair might need to be done to correct it properly. It involved head work as well as carb work. It seems to be a known issue with the '96-'97 model. Do you know if it ever got a recall service check/repair? The bike starts, idles, runs and rides great. Just has a stumble at low RPM excelleration like from 50-60mph. Also does it if making a right-hand turn going slow in 2nd gear then rolling on the throttle slowly. It never seems to do it if riding aggressively or keeping the rpms up a bit. Any feed-back would be helpful

@ Hi, sorry to hear it is still having some issues. We bought it second hand, it was 9 yrs old, low miles. We never had any engine/carb problems, it always ran great. Had to choke it to start in cold weather. We had to replace the steels and fibers. We never received any recall notice from Kawi. The man we got it from didn’’t mention any recall work. No stalling or bogging down. We really enjoyed it and had many trouble free years. That fuel pump was a cheap amazon part, not sure if it meets the fuel pressure demands of the carb? Just grasping???

@ the fuel pump is next on the list of suspects. I took the sidecar off of it and put it on my ‘96 wide glide. I have heard many complaints about the aftermarket fuel pumps for these bikes. Has to do with a ground controlled by the cdi box. Did the original pump fail or just replaced it just in case? Pressure is within spec testing at the carburetor inlet

@ Just in case, I believe the old one was in the bucket of parts I sent with you.

Thank you and I’ll post a follow up after I install the new manifold and gaskets.

Glad the transmission is resolved! You are an amazing mechanic!!!💪🔧😎

still having issues with the carburetor. I’ve completely rebuilt it and replaced the intake manifold and o-rings. Looks like the carburetor has a plugged passage. The bike runs great but it stumbles just off idle. When riding it looses power when accelerating slowly at low rpm’s. Say when turning in 2nd gear then accelerating. Or when riding in top gear at low rpm’s and trying to accelerate. I’m ordering a new carburetor and with follow up afterwards. If you have any info on the carburetor service or can confirm if the bike did this previously. All the electronics look to be in good condition or new. Do you have more info on the head work that was done?

Primary!

⁠primary? Not sure what you are referring to.

Old bikes seem to be my thing. Do care about restoration, only getting them back on the road. Many more miles and smiles

Thank you. It was a lot of work but fun

❤Oh man!! She looks and sounds so good!!!!❤🎉😊

Thank you and please pass the word. Like subscribe and share.

😅

I have already got the parts I needed and the bike is almost back together

My VN2000 second gear. Clashes from 1st to 2nd. Does not jump out of gear. No debris in oil changes. If revved between 1st and 2nd. With clutch in changes with little to no clashing any advise regards 🇦🇺

If it shifts fine with a blip of the throttle the engine idle could be set too low or high. Possibly the shift control arm is out of adjustment or the shifter paw and detent are damaged ​@@Paul-g9c6m

@@fitchpaintingrepairllc9871 thanks for your advice. Ride safe 👌

I have a question. I have a 1996 vn1500e and my 1st gear skips at any more than putting around. Do you knkw where i can get a new 1st gear. Or if it even is that? If you could get back to me that would be awesome.

Tap tap tap after removing all necessary parts and bolts

@@fitchpaintingrepairllc9871 how bout the primary gear mine only moves doesn’t slide off

@@prestonsmith6675 the big nut on the out put shaft? I would recommend strapping it down to the lift or workbench. Use an air impact or a 3-4ft piece of pipe on the breaker bar. To hold it in place you need the special hook tool. I Locked the transmission gear with a cooper washer. I would recommend getting the service manual as well

Thanks!

Depends on what is actually wrong and if the parts can be found to fix it. $1500 just for the labor

Not sure as the speedometer was not work when I bought the bike