I have a 1996 Kawasaki Vulcan 1500 Classic. In first gear, if I accelerate any faster then "slow", after about 15mph, it feels like it pops in and out of gear, and the bike almost feels like it's surging. The surging is probably then engine when if pops out of gear. The rest of the gears are fine. What could be causing this?

What does it feel like when you press the lever up or down and s there any resistance there

Don't think so, two different part numbers.

http://www.bikebandit.com/houseofmotorcycles/1997-kawasaki-vulcan-1500-vn1500a-front-bevel-gear/o/m149756sch61270

1997 Kawasaki Vulcan 1500 = part # 764509

http://www.bikebandit.com/houseofmotorcycles/2004-kawasaki-vulcan-1500-classic-vn1500e-front-bevel-gear/o/m149231sch288585

2004 Kawasaki Vulcan 1500 classic = part # 764585

Does this have a modified (Non-Stock) exhaust system? If so, It's probably the reed valves. (Large bore Kawasaki bikes are known for it) Look at this page for a few fixes: http://www.gadgetjq.com/smogstuffremove.htm

the 96 and 97 vulcan classic 4 speed transmission is garbage. Fixed mine 3 times. still no 2nd gear. Shame on you you Kawasaki.
My advice, drive it off a cliff somewhere and then go buy a honda vtx.

sounds like the gear selector plate plunger is worn or needs a new spring. on most engines a hollow screw @ 3/4" is accessible from under gear box, take it out and stretch the spring and retry to eliminate possibility.

Hi Buddy
There is not an easy solution to your gearbox problem,it is general wear on the 'dogs' or 'shift drum'..The only other thing it could be is wear on the 'external shift mechanism'.
I,ve just rebuilt a 1996 vn1500 classic whitch had the same problem so if you need any advise or step by step photos please email me at '[email protected]'
paul

first gear shift fork is bent.