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Discussion Starter #1
Ok so I have a 2003 Vstar 1100 Custom. Hasn't ran in over a year and a half when I bought it. (said the guy) I've done a ton of work to it since I've got it. Cleaned and re-sealed the gas tank, carbs, ect. When I got the bike the alternator cover was off as well as the starter clutch. I cleaned and re-assembled everything and diffused the-which bolt goes to which hole bomb-and put the cover back on. The problem is, when I put the alternator cover back on, the pedal shifter doesn't spring back. For example when I shift down it stays down, and when I upshift it stays up. So I took the cover back off and hooked everything back up and it shifts fine and returns to center as it should. Any ideas on what this might be? I've already removed the shift shaft and inspected it, if it is in fact bent I cant tell. When I put the cover on I can put all the bolts in finger tight and it stills shifts and returns. When I start tightening them is starts acting up again. Any ideas or help is appreciated fellas. My thoughts are its a bent shiftrod, but like I said if it is its very small, also there isn't any sign of scraping or roadrash anywhere on the bike or anywhere on the left side that would indicate he dropped it and bent it. I feel like it's a very simple fix and its driving me nuts ha.
 

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That's the engine with the side case that slips over the shift shaft? Maybe the bearing in the cover is not seated right and you are actually pushing on the shaft when tightening down the bolts. Make any sense?
 

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Discussion Starter #3
Yes it's the left side cover. I will check the cover but I don't remember seeing a bearing inside the cover. I'll go check and report back
 

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Discussion Starter #4
I fixed it. when I got the bike it was missing the little washer on the outboard side of the shift shaft that butts up to the lock washer on the shaft itself. the one I replaced it with was too thick. Somehow I magically found the original washer under a pair of vice grips. installed it and it works perfectly. Thanks for replying with help though, it got my wheels turning and reminded me of that washer I replaced.
 

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Great! I was just going by the drawings for the bearing. It could be just a bushing or whatnot. It's there with the oil seal. I see the washer now, too, that slips over the shaft after the circlip.
 
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