How To Reassemble Clutch on Kawasaki Vulcan 1500 with Barnett Spring

[@donwolfjr1]

I really appreciate this video!!! Finally, someone actually showing us how the clutch goes back together!! I know I'd be careful enough to do this myself, and will be soon but..this is a great reference for the..." just in case" moment where we're not 100% sure how the hell it went back together!!! Lol. I won't be using the Barnett clutch spring though, I'll be using the Meanstreak spring and the Judges washers set in mine!! The difference between the Meanstreak and the Barnett spring is...the Meanstreak is much more user-friendly than the Barnett spring which...is not!! Lol. And the fumbling around in this video is very annoying but...I'm sure it was to Joe too, trying to hold the camera and show us viewers at the same time! Lol. Still...a great video to have!!! Thanks, Joe!!! : ) Don W., Ohio, USA!!!

[@armyguyz00]

Thanks for watching. I know it was kinda rough video but I had no good reference for putting this back together. So I figured it might help somebody. I’m in Nile’s Ohio so maybe I’ll see ya around

[@MotorheadLars]

Perfect video. All of the info none of the bullshit haha quick and to the point. Thx brother

[@armyguyz00]

Thanks for watching

[@aluheinzel]

Top Viedeo hat mir sehr geholfen danke

[@armyguyz00]

Thanks for watching

[@masonjopes6274]

Did you use a full Barnett clutch kit like the plates too?

[@armyguyz00]

I’m not sure, this bike had the kit already in it.

[@gimmieliberty6514]

the assembly isnt quite correct, at 0.42 both 92022A washers are put onto the shaft with the spacer on top, it should be just one washer, then spacer, then the basket and bearing, [making sure the oil pump gear meshes wth the basket gear] the second washer goes on top of the basket, so this basket is 2mm further out than it should be, so the metal oil gear and the primary drive arent fully engaging across their width, also as we see in the comments below, when the basket is 2mm too high, the pushrods 2mm to short makeing the clutch impossible to dissengage

[@armyguyz00]

You might be right, I have no idea. I sold this bike a while ago. Thanks for the input.

[@tomstrow3306]

Yes, because mine was taken apart, and that washer was on the inside of the basket, the second flat washer

[@MrtrapLive]

I thought the same. Thanx 4 the confirmation. Everything else was great

[@nfnf8529]

Great video! FYI - I don't have air tools to torque and loosen nuts. So, I'm limited to using a 1/2" torque wrench (not air). I have one concern about torque and loosening the 27mm nut using the method of jamming gears.. Are we taking a risk breaking gear teeth by jamming the gears with a screwdriver? Steel on steel? Should I be concerned? Is there another way short of steel on steel to jam the gears to allow the necessary 27mm nut torque using a standard (non-air) 1/2" torque wrench? Thanks for your reply.

[@armyguyz00]

I’m sure there is a better way but this did work for me. I think the impacting motion helped a lot compared to just a 1/2 bar. I would be careful but It should be okay.

[@nathanielselvidge4157]

Great video thank you so much. Should I really soak my plates in oil before doing this?

[@armyguyz00]

I don’t know, everybody says to but I don’t understand why it would matter.

[@ScottMiller-tu3gg]

What type of grease did you use to hold the washers on the shaft when you reassembled?

[@armyguyz00]

Just a little bit of Lucas red N tacky

[@bekkahtheadventurer8559]

Washer order must be different on the 1600’s…. One on the back of the clutch housing, one after per the manual I believe….I’m having a spacing issue with the clutch hub nut and the spring plates. Input shaft just spins when jammed….deeper to dig

[@IanRobinson-oh4yj]

he got the washer order wrong, see my comment above, one washer goes under the basket and one on top....the assembly isnt quite correct, at 0.42 both 92022A washers are put onto the shaft with the spacer on top, it should be just one washer, then spacer, then the basket and bearing, [making sure the oil pump gear meshes wth the basket gear] the second washer goes on top of the basket, so this basket is 2mm further out than it should be, so the metal oil gear and the primary drive arent fully engaging across their width, also as we see in the comments below, when the basket is 2mm too high, the pushrods 2mm to short makeing the clutch impossible to dissengage

[@armyguyz00]

I’m not 100% sure. I sold this bike a while ago.

[@joshpod007]

Thanks for making this video!

[@armyguyz00]

No problem, hope it helped out

[@markchimmy]

Thank you for sharing! I've watched few of your videos and it's very informative and your knowledge is great too!!! Wish you could look at my 2002 kawasaki Vulcan classic 23k and be able to tell me what could be causing a clunk while I shit up or down? should I put a different oil in it? I just got it a week ago and was told by previous owner it was changed not long ago. Please let me know by responding back 🙏 I would greatly appreciate it. Thank you very much!!! and keep up with your videos very educational and informative 👍!!!

[@armyguyz00]

I recommend running rottella T6 5w-40 heavy duty diesel oil in my bikes, I have had no issues and it has all the specs for motorcycle clutches. Kawasaki has a very loud transmission clunk, even on my 2016 vaquero. It might just be how they are built. Thanks for watching

[@markchimmy]

Thank you very much for replying back! I will try using this oil you recommend. 👍

[@RayJohnson-v1g]

I just saw your video on the 1500 clutch. Can you show how to split the casing (removing the parts)? I lost second gear.

[@armyguyz00]

Unfortunately not, I have sold both of my Vulcan 1500s

[@pepelepew2142]

great video thanks!! no bull!!!

[@edvardteath5951]

Oo Barnett 👍👍 perfecto.) 🛠

[@richardmccraw831]

nice video joe. i changed mine the same way but now clutches are ingaged when clutch lever is pull all the way in .did you have thap problem?

[@armyguyz00]

I had similar problem. When clutch master cylinder failed. It’s 3 bolts on other side of bike. Mine has bad fluid and had broke. If you look at the other video of this bike on here I think I go over it

[@richardmccraw831]

@@armyguyz00 we found the prob out the 2nd hand clutch basket was 3cm higher than the old one put old basket back in works good now . but i will check the other video out

[@gimmieliberty6514]

because he put both washers under the spacer, only one washer goes there, the other goes on top of the basket,so your clutch was 2mm higher on the shaft meaning the pushrod was 2mm too short,

[@Reoman1964]

Thanks bro