PDF for most of the mods done on Vulcan - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 7 (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/open?id=1VO...q2sjJ8z88R5-U9

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; 07-05-2019 at 07:21 PM. Reason: Doc and link updated 7/5/19
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post #2 of 7 (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.

KM

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post #3 of 7 (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 7 (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
Hench is online now  
post #5 of 7 (permalink) Old 06-10-2019, 02:51 PM Thread Starter
2003 Vulcan 750/Sidecar
 
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Location: Arkansas
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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
Hench is online now  
post #6 of 7 (permalink) Old 06-10-2019, 03:06 PM
Retired USAF (IYAAYAS)
 
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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
Chris and Shim is offline  
post #7 of 7 (permalink) Old 06-13-2019, 09:46 AM Thread Starter
2003 Vulcan 750/Sidecar
 
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Join Date: Nov 2018
Location: Arkansas
Posts: 78
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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
Hench is online now  
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