Kawasaki Eliminator 125 shifter mechanism replacement

Discussion in 'Road Warriors' started by Krautbikeman, Oct 31, 2012.

  1. Krautbikeman

    Krautbikeman Failed Anger Mgt #$%@#$%^

    Joined:
    Jan 29, 2002
    Oddometer:
    5,518
    Location:
    Deelightful Deland, FL US of A
    I've done about a dozen of these repairs myself and cannot seem to get the procedure down for replacing the right side case cover after I've replaced the shifter mechanism through the case. The clutch actuator (vertically-oriented shaft) that drops in the top of the right side engine cover rotates and has an open space at the bottom resembling a 2-pronged "claw" that is supposed to catch onto the mushroom-shaped rod that extends through clutch pack.

    I can rotate the rod around to make what feels like contact, but not engage it correctly to allow the pull of the clutch lever/cable to rotate the actuator rod around to pull on the mushroom-end of that rod, thereby disengaging the clutch.

    Totally frustrated and discussions with the dealer was like :baldy. I guess the profit from me buying the part wasn't enough. :waysad

    Is there some commonly accepted way to reinstall the right side case cover to align properly with the vertically-oriented rod that drops through the top to the shaft that extends through the clutch pack?
    #1
  2. Bueller

    Bueller Cashin?

    Joined:
    Sep 25, 2003
    Oddometer:
    17,391
    Location:
    Hide Away Hills, Ohio
    Don't know for sure, but it seems to me you'd want to consider scribing alignment marks on the shaft prior to removal to ensure you reassemble with it in the same location/orientation. Beyond that, tell the n00bs to stop dumping the bike(s) :lol3

    Hope all else is well!
    #2