PDF for most of the mods done on Vulcan - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 11 (permalink) Old 06-09-2019, 12:46 PM Thread Starter
2003 Vulcan 750/Sidecar
 
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PDF for most of the mods done on Vulcan

https://drive.google.com/file/d/140v...ew?usp=sharing

This is a doc of most of the mods in one place. I put it together for a new owner I met here in Arkansas.

It was suggested I post it for forum users.

2003 VN750
Velorex 562 sidecar w/trunk
2-wire mod
Headlight power switch
Manual fan switch
Shingigen SH775
Blue wire mod
Yellow wire mod
RLU removed
RR moved
Voltmeter relay wired
Coils direct wired w/relay
TOC MCCTs
handicap mods:
extended foot shift
heel shifter
extended brake pedal

Last edited by Hench; 09-08-2019 at 10:08 PM. Reason: Doc and link updated 7/5/19
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post #2 of 11 (permalink) Old 06-09-2019, 02:36 PM
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Cool. And thanks.
Have "stuck" this thread in "General Discussion" as it covers several areas.

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post #3 of 11 (permalink) Old 06-10-2019, 12:31 PM
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Most excellent. Congratulations on gathering them all together for a one-stop-shopping document.

I'm thinking of both relocating my RR and going with a MOSFET. I had hoped the MOSFET section would have offered more pics. I'm primarily a visual guy and grasp things much quicker if I can see it visually done in sequence. Perhaps later on some enterprising soul can photo-document said improvement for us unimaginative sorts.

Regardless, this is a good source document to download and have ready for us. On behalf of the 750 community at large, thank you for this public service!! Good work!

TOC MCCTs
Saddlebags, hard mounted
Fork mounted tool bag (now hard mounted)
Relocated rear turn signals
LED turn signals, brake lights and running lights
LED license plate frame
Engine Guard and Highway pegs
National Cycles Low Boy Heavy Duty windshield
Home made lowers (nice)
Custom seat (made by a local guy)
Iridium plugs (DPR7EIX-9)
Shenko 230 Tour Master tires at 11,123 miles
Splines lubed at 11,123 miles
Luggage rack
Light bar with LED lights

Last edited by Chris and Shim; 06-10-2019 at 12:33 PM.
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post #4 of 11 (permalink) Old 06-10-2019, 02:36 PM Thread Starter
2003 Vulcan 750/Sidecar
 
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Thanks Chris,

I mounted my R/R out in the wind as shown. Spockster suggested I add a pic of an alternate location which I'm doing.

Earlier in doing the mods to my bike I saw a MOSFET wiring diagram but couldn't find it again.

In a nutshell the basic wiring of MOSFET is any of the yellow stator wires go in any of the 3 connections on the grey plug. So you have the three stator wires (one each) to the 3 connections. Then you run wires from the black plug to the battery. Use 12 ga. red and black. On the black plug the positive (red) goes to the battery positive terminal. The black goes to the negative terminal.

On the black plug the red wire goes in the left most connection and the black wire goes in the right most, leaving the middle one empty.

Look at the picture showing the MOSFET mounted and you'll see the wire order.

And now I found a mosfet wiring diagram and alternate rr mounting method for the doc

The worst for me in installing the thing was the wiring kit was just that! A kit. Plugs had to be assembled with inserts, gaskets etc.

The alternate mounting position is to make a bracket and mount the R/R over the JB and behind the left side cover. I'll put the pic in the doc.
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2003 VN750
Velorex 562 sidecar w/trunk
2-wire mod
Headlight power switch
Manual fan switch
Shingigen SH775
Blue wire mod
Yellow wire mod
RLU removed
RR moved
Voltmeter relay wired
Coils direct wired w/relay
TOC MCCTs
handicap mods:
extended foot shift
heel shifter
extended brake pedal
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post #5 of 11 (permalink) Old 06-10-2019, 02:51 PM Thread Starter
2003 Vulcan 750/Sidecar
 
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PDF is updated with mosfet wiring diagram and alternate RR location pic.

2003 VN750
Velorex 562 sidecar w/trunk
2-wire mod
Headlight power switch
Manual fan switch
Shingigen SH775
Blue wire mod
Yellow wire mod
RLU removed
RR moved
Voltmeter relay wired
Coils direct wired w/relay
TOC MCCTs
handicap mods:
extended foot shift
heel shifter
extended brake pedal
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post #6 of 11 (permalink) Old 06-10-2019, 03:06 PM
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I'll probably just wait until my stock RR craps out and then put in a MOSFET in a re-located position.

TOC MCCTs
Saddlebags, hard mounted
Fork mounted tool bag (now hard mounted)
Relocated rear turn signals
LED turn signals, brake lights and running lights
LED license plate frame
Engine Guard and Highway pegs
National Cycles Low Boy Heavy Duty windshield
Home made lowers (nice)
Custom seat (made by a local guy)
Iridium plugs (DPR7EIX-9)
Shenko 230 Tour Master tires at 11,123 miles
Splines lubed at 11,123 miles
Luggage rack
Light bar with LED lights
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post #7 of 11 (permalink) Old 06-13-2019, 09:46 AM Thread Starter
2003 Vulcan 750/Sidecar
 
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When I installed my analog volt meter I noticed the needle "swinging" at idle and speed. Chalked it off to vibration. Then I found the insulation on the stator connections discolored and bubbled. I have a spare RR that I put in and found the old RR was failing. Might have taken stator with it as some here have said. Left the "new" OEM RR in until I got a Shindigen SH775BA MOSFET. Good RR and the stator connects run cool.

2003 VN750
Velorex 562 sidecar w/trunk
2-wire mod
Headlight power switch
Manual fan switch
Shingigen SH775
Blue wire mod
Yellow wire mod
RLU removed
RR moved
Voltmeter relay wired
Coils direct wired w/relay
TOC MCCTs
handicap mods:
extended foot shift
heel shifter
extended brake pedal
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post #8 of 11 (permalink) Old 09-08-2019, 10:31 PM Thread Starter
2003 Vulcan 750/Sidecar
 
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What the PDF covers

Oil and filter change – what to do the first time
Spline lube – the gear box at the rear wheel
Air filters – those oblong chrome things on each side of the bike.
Battery – if one is not already installed, get a new AGM battery. If one is already in there check the date. If 3 or more
years old get a new one. Read the service manual on replacing the battery.
Spark plugs – put in some iridium plugs. (DPR7EIX9) Don’t gap them they’re already set. Get an 18mm
/plug wrench.

Reliability mods:
Blue wire mod – bypass JB headlight relay
Two wire mod – bypass JB start relay
Regulator relocation – moves from under battery box to out in the wind for better cooling
MOSFET regulator upgrade – a better technology RR
Volt meter – good upgrade to see what the charging system is doing
TOC MCCT install – if/when the ACCTs fail
Coil direct wire – wires coils directly to battery via standard relay
Pickup coil mod
Other mods:
Reserve Lighting mod – bypass RLU (can be removed)
Rewiring the bike – not for the faint of heart
Floorboards diagram DIY – improves the ride

Testing things:
Testing the stator – if it’s not charging
Testing the OEM RR – if it’s not charging
Not running right? Some trouble checks
Trouble shooting stator & RR – more info

I’ve included the procedure for replacing the stator without fully removing the engine.

Other things:
Carb synching – how to
Carb removal – how to
Annotated wiring diagram – some explanations added
Homemade carb synchronizer – you should have one if you think you need to synch
Cooling fan mod – manual switch
Clutch release lever adjustment – bottom of engine
Shifter repair – pawl/spring
Clutch basket mod – clutch grinding
Replace stator – engine tip-out method
Ear shave – remove stock air filters for K&N filters
Vulcan slang – terms used on the forum. Helps in searching problems
roadpouring and MSattler like this.

2003 VN750
Velorex 562 sidecar w/trunk
2-wire mod
Headlight power switch
Manual fan switch
Shingigen SH775
Blue wire mod
Yellow wire mod
RLU removed
RR moved
Voltmeter relay wired
Coils direct wired w/relay
TOC MCCTs
handicap mods:
extended foot shift
heel shifter
extended brake pedal
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post #9 of 11 (permalink) Old 09-09-2019, 08:06 AM
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You're doing God's work

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'86 VN750 with the following work done to it, after sitting for 19 years:
John 8:44
REV 2:9
REV 3:9
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post #10 of 11 (permalink) Old 09-09-2019, 01:54 PM Thread Starter
2003 Vulcan 750/Sidecar
 
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Thanks! I put this together for a young rider. The VN750 is his first motorized vehicle and he lives out in the country doing his own "fixins". Has the service manual but was frustrated by the way it sometimes makes you refer to various chapters in a procedure. The guys here have written comprehensive and straight-forward how-tos. I just pulled them all together.

2003 VN750
Velorex 562 sidecar w/trunk
2-wire mod
Headlight power switch
Manual fan switch
Shingigen SH775
Blue wire mod
Yellow wire mod
RLU removed
RR moved
Voltmeter relay wired
Coils direct wired w/relay
TOC MCCTs
handicap mods:
extended foot shift
heel shifter
extended brake pedal
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