Just to let you know that I performed the keyhole surgery and successfully completed the repair. At times I thought it was a windup, but no, a lot of persistence and patience, it really does work 😀 Thank you for having the vision to attempt it in the first place 👍🏻
Hi Jason, Yes, just as described in Gary’s video. Made the same tool, and it works. I’ve almost done 800 miles since doing it, and my bike is running fine.
Thanks Gary for the video. I just got the clip on the new gear. I purchased a endoscope camera online, could not have done this without it. People should know that the clip can fall off, as it happened to me. I had applied to much pressure trying to get it off the shaft and stretched the clip. Luckily I had ordered a new clip to use to get the needle nose pliers to fit. It took me hours to get the clip back in place and back on the new shaft. I put the camera in the 1-1/8” hole and used the home made tool in the same hole. The length of the needle nose pliers I used was 2-3/8” long. I just barely had enough length I would recommend a bit longer. When taking the clip off the shaft I recommend blocking the bottom hole (hell hole”) with a shop towel to prevent the clip from falling down in the oil pan. Also I tapered the new shaft to help that clip slide into the notch on the shaft. It can be done, and I am not very mechanical inclined. Thanks again Gary, could not have done this without your video.
Good to hear. Next time you clean the oil pump pre-screen be super careful not to allow any metal shavings, (that might have gotten into the pan), to find their way past that screen or they may cause the pump to freeze up and you’ll be back to square one. I’m not sure how your clip fell. I thought I was pretty ham handed and it never slipped off. I didn’t think there was enough room. That would really spoil the fun. Congrats.
There was a video link that I shared until recently because it’s creator made it private. However I’m going to be doing some more work on this bike starting this weekend so I’ll make some measurements and post them soon.
Hi Gary ..im in the process of buying a 99 nomad with 7000 miles on it ..I absolutely love the bike ..I had a couple of questions ..if you would be so kind ....should I go ahead with the purchase ..if so should I just ride it out and see what happens ?or should I do this right away ?
@@irishmikeful Tough call but when the gear goes bad, the oil pressure is gone so you could be stranded. It’s a pain is the ass job to do on a running bike. I’d probably ride it but if you do, and the oil light comes on, don’t think about it. Get to a safe place and shut it down.
Hi Gary, great video and info you've supplied over the years. I am about to strip my iron lady down to see if i have the same problem, UK based. Would you happen to know the OEM part number? Or even a link to it? Many thanks, Andy L
I’m doing this now and my clip slip off the shaft so now I’m struggling to get the washer seated then flip the clip to get the pliers on and it’s just a pain in the ass. It’s like a 3 hour job if you don’t do it right away like this video.
I believe the larger hole was a 1" and the camera hole was 1/4 to 3/8" (just enough to get the camera in and have the ability to move it. When I started I wasn't certain where to drill so I got a close as I could without disturbing the "v" just below the bigger hole, since I didn't want to weaken the case. Pretty much estimated the best angle to see what I was doing from the camera hole. Also, there was a video which has since been removed that did something similar but he didn't use a camera and his tool was different (I don't remember what it looked like now). I knew the camera would help and I liked the idea of making the tool by modifying a readily available tool. Don't forget you must never let any metal shavings get past the oil pump pre-screen because if they get sucked into the pump you will be splitting the cases and replacing a broken pump. All the best...
Fantastic video! Thank you for posting this. These old bikes will run forever with just a little TLC! Would drilling a larger access hole be possible/make the job easier? Mind me asking what brand/cost was the bore scope?
I couldn't say for sure if a larger access hole is possible but I doubt it would make the job easier unless it was significantly bigger and I would be concerned that could weaken the integrity of the case. The scope is still on Amazon for $37.98. TODSKOP 5.5mm WiFi Borescope. Not fancy at all. It connected to my IPad via WiFi. Thank you!
Gary, help! Disaster has struck. The piece I was cutting out fell in the engine with no sign of it with the scope!!! Any ideas what to do? Cheers Andy L
Hi Gary, unfortunately I couldn’t find it! So after 4 oil changes and filters, I am trusting to luck that it stays at the bottom of the pan 🙏🏻 I’ve done a couple of hundred miles on her, and she’s not missed a beat 😀 Hopefully, that’s how it stays. Thanks again from over the pond 👍🏻 Andy L
Hey Gary, I have a 97 Vulcan Classic, its a vn1500d, when you replaced the gear, did it have 2 washers behind it? Looking at different diagrams, they seem to show that there is, but when i bought this bike, the gear was already gone so just the shaft is left
Seems like a huge pain in the ass I hope I don't have to do this on mine anytime soon. What if that clip falls inside the motor while your trying to put it back on? Just so I know for the future
Yes. Used a vacuum to catch most of the shavings but there were some that ended up inside. Washed most of them through with a quart of oil but be super careful at the next oil change because the pre-screen will catch any leftover metal so you have to be certain not to leave any behind when you clean the pre-screen. If any get past it into the I’ll pump it could freeze and break and you’ll be opening the cases to replace it anyway.
@@garyl6343 how is this working for you? Good I hope..how much oil loss is there? I have a 99 Vulcan 1500 Classic with 19k it’s my first bike and I’m not the most knowledgeable yet somewhat mechanically incline as I grew up working on cars and stuff with my grandpa and dad, but I’m thinking about getting the judge kit as well. I talked to Bob “the judge” today 10/18/21 and he told me to check out the POG first and oil pressure and that it should be at 80-100lbs, then give him a call back with the details I’ve found, I would like to not have to split my case open and replace a whole lot more but instead, go this route. I just thought I should look into if you actually found you did loose any oil and if you did how significantly and if not then hell yeah this will be the route I take.
@@phillipyelle7719 That bike didn’t have an oil gauge, just a light. I can only say it worked well at the time but I don’t own it and can’t report on it now.
@@garyl6343 my apologies for the error, he said they have 80-100lbs of pressure and your to undo the hoses at the back of the rear cylinder head slightly and then turn it over and if you turn it over and your getting oil coming out you have pressure, if your not getting pressure then your oil pump has quit or gear has broke and need to go in and inspect. My oil pressure light is on not oil gauge light..
Gary, during the drilling process how are the drilling chips and dust contained so that they do not contaminate or cause damage to internal parts of the engine? Have a most awesome afternoon!
I used a vacuum but you do have to be very careful the next time you remove the oil pump pre-screen because it is the last line of defense for any shavings that got missed. That is the sketchiest part of doing this. If any get into the oil pump you’ll be splitting the cases.
@@jeffalessi Yes. That’s it. BTW, the owner of the Vulcan I was going to work on decided to hold off indefinitely so I can’t make this measurements after all however I cut the big hole with a 1.5 inch hole saw and you can see the position pretty well in the video. You could use a smaller hole I think. You just need room to open the pliers enough to open the c-clip. The hole for the camera just needs to be big enough to allow the bend which isn’t much.
@@garyl6343 Gary, doe a separate hole need to be drilled for the camera? On a separate note is there a small factory hole under the gear near the bottom edge of the case? I do not have the clutch cover off the engine yet. Thank you for answering all the follow-up questions I have been asking.
I'm so nervous I have the ability to do this but still so nervous , typical that there's so much to do for a darn lock washer , debating between this and complete teardown on fixed income and summer is getting closer to end everyday
The only risk I see is the shavings from drilling. They absolutely must not get past the pre screen. If successful, you’re back on the road with an OEM steel gear.
I really really appreciate this video it's going to help me out so much it seems pretty straightforward I've had nothing but bad luck I got hit by a car Deming me disabled when I was on a motorcycle then I had a motorcycle stolen and seeing this video and save my life I just have to save up to get materials that you use again I thank you for the video I hope it works for me
It can be done, but it is definitely not that simple to make that tool fit…. You better be very patient and very steady, and very mechanically inclined …. I had to walk away from the job 10 times…. Ended up popping it on with a bent screwdriver. 😂 Modify the snap ring to clip on ever so easily while I was holding it in my hand, and then just spun it on with a flat screwdriver bent to fit up in there…. It almost took my soul….. 😭
Just to let you know that I performed the keyhole surgery and successfully completed the repair. At times I thought it was a windup, but no, a lot of persistence and patience, it really does work 😀
Thank you for having the vision to attempt it in the first place 👍🏻
I have to do the same job myself next week. I ordered the original steel gear from kawasaki. Did you drill a hole in the casing?
Hi Jason,
Yes, just as described in Gary’s video. Made the same tool, and it works. I’ve almost done 800 miles since doing it, and my bike is running fine.
Thanks Gary for the video. I just got the clip on the new gear. I purchased a endoscope camera online, could not have done this without it. People should know that the clip can fall off, as it happened to me. I had applied to much pressure trying to get it off the shaft and stretched the clip. Luckily I had ordered a new clip to use to get the needle nose pliers to fit. It took me hours to get the clip back in place and back on the new shaft. I put the camera in the 1-1/8” hole and used the home made tool in the same hole. The length of the needle nose pliers I used was 2-3/8” long. I just barely had enough length I would recommend a bit longer. When taking the clip off the shaft I recommend blocking the bottom hole (hell hole”) with a shop towel to prevent the clip from falling down in the oil pan. Also I tapered the new shaft to help that clip slide into the notch on the shaft. It can be done, and I am not very mechanical inclined. Thanks again Gary, could not have done this without your video.
Good to hear. Next time you clean the oil pump pre-screen be super careful not to allow any metal shavings, (that might have gotten into the pan), to find their way past that screen or they may cause the pump to freeze up and you’ll be back to square one. I’m not sure how your clip fell. I thought I was pretty ham handed and it never slipped off. I didn’t think there was enough room. That would really spoil the fun. Congrats.
Great video I want to do this to my Vulcan 1500 but drilling into the motor is sketchy may give it a try one day thanks again
Great job! Just a surgical operation on the engine.
Thank you for your clear and detailed explanations throughout the video.
Gary, is there a video of how and where to drill the access hole for the clip? Thank you and have a most awesome evening!
There was a video link that I shared until recently because it’s creator made it private. However I’m going to be doing some more work on this bike starting this weekend so I’ll make some measurements and post them soon.
@@garyl6343 Gary, Wow, Thank You for the extremely expeditious reply and going out of your way to help! Have a most awesome evening! Jeff...
Hi Gary ..im in the process of buying a 99 nomad with 7000 miles on it ..I absolutely love the bike ..I had a couple of questions ..if you would be so kind ....should I go ahead with the purchase ..if so should I just ride it out and see what happens ?or should I do this right away ?
@@irishmikeful Tough call but when the gear goes bad, the oil pressure is gone so you could be stranded. It’s a pain is the ass job to do on a running bike. I’d probably ride it but if you do, and the oil light comes on, don’t think about it. Get to a safe place and shut it down.
Hi Gary, great video and info you've supplied over the years. I am about to strip my iron lady down to see if i have the same problem, UK based. Would you happen to know the OEM part number? Or even a link to it? Many thanks, Andy L
Do you have to plug that drilled hole up after or is it okay to leave it open planning on trying this with my bike oil gear just went
You don't have to plug the hole. The oil finds it way down into the pan either way.
Do all these models have that hole to do this surgery or are there some models you have to split the case?
Could you post the measurements from that tool? Maybe with a caliper or something?
I need to do this process
I’m doing this now and my clip slip off the shaft so now I’m struggling to get the washer seated then flip the clip to get the pliers on and it’s just a pain in the ass. It’s like a 3 hour job if you don’t do it right away like this video.
@Gary L Hey again Gary. Would that tool be for sale or would you be willing to make one and sell it?
How did you know where to drill and what size drill did you use?
I believe the larger hole was a 1" and the camera hole was 1/4 to 3/8" (just enough to get the camera in and have the ability to move it. When I started I wasn't certain where to drill so I got a close as I could without disturbing the "v" just below the bigger hole, since I didn't want to weaken the case. Pretty much estimated the best angle to see what I was doing from the camera hole. Also, there was a video which has since been removed that did something similar but he didn't use a camera and his tool was different (I don't remember what it looked like now). I knew the camera would help and I liked the idea of making the tool by modifying a readily available tool. Don't forget you must never let any metal shavings get past the oil pump pre-screen because if they get sucked into the pump you will be splitting the cases and replacing a broken pump. All the best...
Fantastic video! Thank you for posting this. These old bikes will run forever with just a little TLC!
Would drilling a larger access hole be possible/make the job easier? Mind me asking what brand/cost was the bore scope?
I couldn't say for sure if a larger access hole is possible but I doubt it would make the job easier unless it was significantly bigger and I would be concerned that could weaken the integrity of the case. The scope is still on Amazon for $37.98. TODSKOP 5.5mm WiFi Borescope. Not fancy at all. It connected to my IPad via WiFi. Thank you!
@@garyl6343 thank you so much!
@@garyl6343 it's on sale, $31.99 !
@@MikeZyouthpastor That one is slightly different. Not sure if it matters but the one I bought is still on there for $37.98. Same company.
Gary L I would make sure you purchase the borescope with the 5.5 mm the one I used was 8 mm and it was not fun. Do yourself a favour.
Gary, help! Disaster has struck. The piece I was cutting out fell in the engine with no sign of it with the scope!!! Any ideas what to do?
Cheers
Andy L
Glad you got past this. Sorry I didn’t see it in time to respond. How did you end up finding the piece?
Hi Gary, unfortunately I couldn’t find it! So after 4 oil changes and filters, I am trusting to luck that it stays at the bottom of the pan 🙏🏻
I’ve done a couple of hundred miles on her, and she’s not missed a beat 😀 Hopefully, that’s how it stays.
Thanks again from over the pond 👍🏻 Andy L
@@AndyLawman-iz3sq The screen will keep it from being sucked into the pump. I’ll add some prayers. All the best. Gary
real good deal, i did it, gonna go buy a lottery ticket
I didn't realize you have to drill a hole. That doesn't hurt the motor at all (metal shavings aside - I'm just talking oil flow)?
The oil that comes through the holes just flows down into the pan.
Any chance you know what size pliers you used and the measurements for the bends I gotta do this soon.
Hope this helps:
th-cam.com/video/gywOsXnWaIQ/w-d-xo.html
Yes that will help greatly thank you very much.
Getting ready to mine! Have my hole drilled and everything out, just nervous about "surgery"!
Hey Gary, I have a 97 Vulcan Classic, its a vn1500d, when you replaced the gear, did it have 2 washers behind it? Looking at different diagrams, they seem to show that there is, but when i bought this bike, the gear was already gone so just the shaft is left
It looks like two on this OEM parts diagram
www.motosport.com/oem-parts/kawasaki/1997/vulcan-1500-classic-_-vn1500d/oil-pump~oil-filter
yes that is the diagram that i was looking at also, so when i replace the gear I should have 2 washers on there?
@@ultima1391 That is how I read it also
Seems like a huge pain in the ass I hope I don't have to do this on mine anytime soon. What if that clip falls inside the motor while your trying to put it back on? Just so I know for the future
THANK YOU!!!
Did you drill the small hole above for the camera?
Yes. Used a vacuum to catch most of the shavings but there were some that ended up inside. Washed most of them through with a quart of oil but be super careful at the next oil change because the pre-screen will catch any leftover metal so you have to be certain not to leave any behind when you clean the pre-screen. If any get past it into the I’ll pump it could freeze and break and you’ll be opening the cases to replace it anyway.
Hello Gary L, what did you do with the access hole? Did you have to cover it or seal it up again?? Or, did you leave it as is, opened.
I left it. Any oil splashing through will drain into the pan. All the best, Gary
@@garyl6343 how is this working for you? Good I hope..how much oil loss is there? I have a 99 Vulcan 1500 Classic with 19k it’s my first bike and I’m not the most knowledgeable yet somewhat mechanically incline as I grew up working on cars and stuff with my grandpa and dad, but I’m thinking about getting the judge kit as well. I talked to Bob “the judge” today 10/18/21 and he told me to check out the POG first and oil pressure and that it should be at 80-100lbs, then give him a call back with the details I’ve found, I would like to not have to split my case open and replace a whole lot more but instead, go this route. I just thought I should look into if you actually found you did loose any oil and if you did how significantly and if not then hell yeah this will be the route I take.
@@phillipyelle7719 That bike didn’t have an oil gauge, just a light. I can only say it worked well at the time but I don’t own it and can’t report on it now.
@@garyl6343 my apologies for the error, he said they have 80-100lbs of pressure and your to undo the hoses at the back of the rear cylinder head slightly and then turn it over and if you turn it over and your getting oil coming out you have pressure, if your not getting pressure then your oil pump has quit or gear has broke and need to go in and inspect. My oil pressure light is on not oil gauge light..
@@garyl6343 so the hope worked fine.
Gary, during the drilling process how are the drilling chips and dust contained so that they do not contaminate or cause damage to internal parts of the engine? Have a most awesome afternoon!
I used a vacuum but you do have to be very careful the next time you remove the oil pump pre-screen because it is the last line of defense for any shavings that got missed. That is the sketchiest part of doing this. If any get into the oil pump you’ll be splitting the cases.
@@garyl6343 Where is the pre screen located? Thank you for all your help.
Is this the pre screen? th-cam.com/video/JPi6sOkv7So/w-d-xo.html
@@jeffalessi Yes. That’s it. BTW, the owner of the Vulcan I was going to work on decided to hold off indefinitely so I can’t make this measurements after all however I cut the big hole with a 1.5 inch hole saw and you can see the position pretty well in the video. You could use a smaller hole I think. You just need room to open the pliers enough to open the c-clip. The hole for the camera just needs to be big enough to allow the bend which isn’t much.
@@garyl6343 Gary, doe a separate hole need to be drilled for the camera? On a separate note is there a small factory hole under the gear near the bottom edge of the case? I do not have the clutch cover off the engine yet. Thank you for answering all the follow-up questions I have been asking.
Can you make me one of those tools and how much
You need the market that tool
I guess I’ll make a couple of them and see how it goes
I'm so nervous I have the ability to do this but still so nervous , typical that there's so much to do for a darn lock washer , debating between this and complete teardown on fixed income and summer is getting closer to end everyday
The only risk I see is the shavings from drilling. They absolutely must not get past the pre screen. If successful, you’re back on the road with an OEM steel gear.
I really really appreciate this video it's going to help me out so much it seems pretty straightforward I've had nothing but bad luck I got hit by a car Deming me disabled when I was on a motorcycle then I had a motorcycle stolen and seeing this video and save my life I just have to save up to get materials that you use again I thank you for the video I hope it works for me
what year is the bike
1999
GREASE ON THE DRILL BIT A LOT OF IT STOPS SHAVINGS FROM GOING IN THE ENGINE
It can be done, but it is definitely not that simple to make that tool fit….
You better be very patient and very steady, and very mechanically inclined …. I had to walk away from the job 10 times…. Ended up popping it on with a bent screwdriver. 😂
Modify the snap ring to clip on ever so easily while I was holding it in my hand, and then just spun it on with a flat screwdriver bent to fit up in there…. It almost took my soul….. 😭
👍👍👍👍💪💪💪
@Gary L
❤💯👍👍👍👍👍👍👍