The adventure of disassembly has begun... - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 10 (permalink) Old 12-09-2009, 07:53 AM Thread Starter
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The adventure of disassembly has begun...

Hello again!

I had a bad day and the weather was terrible so I came home and decided the time had come, there would be no more putting off the inevitable. Well I had to get myself into the proper mindset because I have very little mechanical prowess and I have this terrible feeling that I might not get her back together in time for spring, but I certainly can't run her any longer in the shape she's in!

I pulled the tank off, removed the battery, disassembled the ears, and disconnected the hoses on the carbs. I wanted to remove the air box, but the Clymer tells me the engine has to be pulled to do this. I also wanted to pull the carbs off the bike so I could tear them down for cleaning and a rebuild, but I wasn't prepared for draining the fluids at this point, so I stopped for the day. As I was sitting looking at her, I wondered if I couldn't just CUT the air box out. I'd like to do an ear shave, so would it be necessary to keep the air box? Can I cut the thing out without causing any problems? It seems that by cutting this piece of plastic out of the way I should be able to get my big hands in between the cylinders to pull the carbs. Also, I have an oil pan that I use to do oil changes on my vehicles, but I've never drained a cooling system before- Is there anything special I need to use to catch the coolant? And finally, I misidentified where the oil was coming out of the cylinders.. The rear cylinder is definitely the culprit, but rather than oil collecting between the cylinders at the bottom of the "V", it seems to be just behind and at the base of the rear cylinder.

Today when I get the opportunity, I will be snapping more pix to post. This thread will serve as the place where I follow up with the progress (or lack thereof) on this project, and as always, your guidance and input will be much appreciated. If anyone has any tips on how far I should disassemble her, or the airbox, or getting the carbs out, I'm certainly open to any feed back- I'm clearly out of my element here.

Thanks again for your support.

NIL ILLEGITIMUS CARBORUNDUM

Phil aka Art
"Vanessa"
1995 VN 750 (bought as 2nd owner 11/2008)
26,440 miles
MF Battery
Stator replaced (55 Days!)
V&H Cruisers
Relocate rear turn signals
Highwayman Saddlemen bags
Wingerline Highway bars
Ear Shave
Rejet carbs
R/R relocate
Coastered
Kuryakin ISO Duallys all around
HD Heritage seat
12" ape hangers

To Do:
Some sort of new grips
Mirrors
Paint Job- should I do it myself?
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post #2 of 10 (permalink) Old 12-09-2009, 09:15 AM
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Because antifreeze (ethylene glycol) is hazardous, you should try to collect as much as you can and take it to a radiator shop for recycling. If you have pets, make sure they can't get to it. It smells "sweet" to them and relatively small amounts can kill.

I'm keepin' all the left over parts. I'm gonna use 'em to build another bike!
_____________________________________________
"Black Beauty"
1989 VN750 acquired December, 2008, 6,711 miles
Currently 23,298 miles

Old Blue
2001 Honda CMX250 Rebel acquired July, 2008

1987 VN750 project bike, acquired August, 2009, 33,000 miles and balancer sticking out of the case, currently awaiting attention and parts
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post #3 of 10 (permalink) Old 12-09-2009, 11:01 AM
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If you are going to remove the engine, just wait and get the box out then. You can sell it on ebay.

02 honda sabre 1100
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post #4 of 10 (permalink) Old 12-09-2009, 02:59 PM Thread Starter
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I've drained antifreeze from a car before but haven't figured out what to use on the bike- which sits relatively closer to the ground than my car, but I will certainly recycle it.

As for the engine, I was hoping not to pull it. And honestly, how much would someone pay for the air box? Is it really worth that hassle? I'm much happier to cut the damn thing out so I can get these carbs off. I'm almost certain the carbs are the issue. I never had any oil leakage before I put the thing in the shop, but the "mechanics" who did the work did a terrible job on everything else I'm wondering how poorly they reassembled the carbs. I'm hoping not to have to rebuild the engine but will do whatever is called for to get her back on the road.

This whole experience has also been the proverbial straw that broke the camel's back.. I'm officially in the marked for a NEW (no more used equipment for me) bike. I'm shopping online and hoping to make some pilgrimages to dealers.. I really want to buy in the off season so I can take advantage of some lower pricing

NIL ILLEGITIMUS CARBORUNDUM

Phil aka Art
"Vanessa"
1995 VN 750 (bought as 2nd owner 11/2008)
26,440 miles
MF Battery
Stator replaced (55 Days!)
V&H Cruisers
Relocate rear turn signals
Highwayman Saddlemen bags
Wingerline Highway bars
Ear Shave
Rejet carbs
R/R relocate
Coastered
Kuryakin ISO Duallys all around
HD Heritage seat
12" ape hangers

To Do:
Some sort of new grips
Mirrors
Paint Job- should I do it myself?
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post #5 of 10 (permalink) Old 12-09-2009, 06:14 PM
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If your coolant is relatively new and you want to reuse it, just make sure the container you drain into has been well cleaned out. If there is still some debris floating on the coolant, I put a couple of thicknesses of cloth for a filter in a funnel and pour it into a gallon jug for storage.

Gordon

1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/11-vn750-general-discussion/9127-top-ten-items-you-would-suggest-new-owner-do-his-new-ride.html
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post #6 of 10 (permalink) Old 12-09-2009, 08:02 PM Thread Starter
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So far so good!

I've gotten the coolant and oil drained and I tore down the air filters as well as the coolant filler assembly and disconnected everything from the carbs... almost

In disconnecting the carb-to-cylinder hoses, I've hit a snag. Since I cant get the air box out (and I'm trying not to destroy it) I have experimented with every screw driver in the man cave trying to reach the screws to loosen them according to the Clymer directions. Unfortunately, the hose attached to the front cylinder has one clamp where the screw head is stripped so it's hard pressed to let the driver bite, and the rear hose is in such an odd angle I can't reach it! I need a longer and thinner driver to reach these screws- Looks like it's time to buy my first new tool for the job!

I'm calling it a night after 3 hours of work today. I'll clean up and think things over before attacking it once more tomorrow before I start getting creative with getting to these screws.

Now for some clarification.. Are the carbs only mounted to the cylinders by these small hoses? So if I can loosen either clamp on either hose, I should be able to work the carbs free? And is there a way to disconnect the hoses that go into the air box (I learned that is called the SURGE BOX today)> If I could get these hoses free, I would be able to get my big hands in there to loosen these screws easier

Thanks for letting me vent, and as always, your feedback is appreciated!

NIL ILLEGITIMUS CARBORUNDUM

Phil aka Art
"Vanessa"
1995 VN 750 (bought as 2nd owner 11/2008)
26,440 miles
MF Battery
Stator replaced (55 Days!)
V&H Cruisers
Relocate rear turn signals
Highwayman Saddlemen bags
Wingerline Highway bars
Ear Shave
Rejet carbs
R/R relocate
Coastered
Kuryakin ISO Duallys all around
HD Heritage seat
12" ape hangers

To Do:
Some sort of new grips
Mirrors
Paint Job- should I do it myself?
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post #7 of 10 (permalink) Old 12-14-2009, 09:47 PM Thread Starter
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I'll say it again.. I am NOT a mechanic!

I am, however, learning

Thanks to all the great help from this forum and the friends I've made from joining it, I have successfully removed the air box and ears as well as the carbs. Granted, I decided to muscle the airbox out rather than dropping the engine. At first I thought the saws-all was the way to go as I ripped it straight up from where the ears came out and along the underside of the frame cutting the air box almost in half. I then saw the frame and wiring would present a problem so I grabbed the tin snips and cut the box out in 3 pieces. I was instantly happy with the fact that now I would be required to do an ear shave and re-jetting of the carbs, how much nicer I think Vanessa will look with the ears gone, AND the fact that removing the air box gave me SO much more room to get at the carbs!

I pretty much have the whole cooling system disassembled and the fuel system. I'll take some good pix and post them hopefully tomorrow.

NIL ILLEGITIMUS CARBORUNDUM

Phil aka Art
"Vanessa"
1995 VN 750 (bought as 2nd owner 11/2008)
26,440 miles
MF Battery
Stator replaced (55 Days!)
V&H Cruisers
Relocate rear turn signals
Highwayman Saddlemen bags
Wingerline Highway bars
Ear Shave
Rejet carbs
R/R relocate
Coastered
Kuryakin ISO Duallys all around
HD Heritage seat
12" ape hangers

To Do:
Some sort of new grips
Mirrors
Paint Job- should I do it myself?
artemis_f0wl is offline  
post #8 of 10 (permalink) Old 12-15-2009, 05:08 PM
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Best of luck with it. I have removed the carbs on my '93 without removing the "surge tank", it is tedious, but can be done. I actually like the ears, they give the bike a distinctive look that newer Harley copy cruisers don't have. Also, I don't want to mess with jetting, I still have the factory jetting, and believe that is best for long term reliability. I did remove all the emissions crap, and the complete air injection system, and plugged all the holes. I have 43,000+ miles on my '02 already, and hope to get well over 100,000 out of it. Then it will be time for a Goldwing. Jerry.

I am a motorcyclist, NOT a biker.


1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike
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post #9 of 10 (permalink) Old 01-06-2010, 03:04 PM Thread Starter
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Well.. the process is almost complete!

Thanks again to all of you who have helped me get through this. I'm way out of my element here but it's nice to have a support network to get this job done! I'm really regretting having put Vanessa in the shop for so long through the summer considering how well I've handled this whole process so far- probably could have saved myself some time and money!

Anyway, the carbs are re-jetted. It was quite an adventure getting them off. I decided to remove the air box after all and I'm glad I did. It was much easier to get the carbs off with out that bulky piece of plastic in my way and I can only imagine how hard it would have been to get them back on the bike without removing it. The ear shave really changes the look of the bike. I'm extremely happy with it overall.

Tonight, we'll be putting the coolant and oil back in (she was due for a change of both I'm sure) as well as getting the rest of the bike back together (I hope). The only thing standing in my way at this point seems to be the need to add coasters since I have eliminated the whole hose setup. While I do want to buy a nice shiny set of coasters, I'm wondering if vacuum caps will work in the interim?

I'm terrible with pix- I found it extremely difficult not to muck up my camera while working on the bike and having so much oil and grime on my hands. I have a few and will try to snap some more before I put her all back together- sorry for the fail there.

I really appreciate all the help and support as well as the friendships I'm developing thanks to this site! It's been great getting to know you all and I hope to be able to give back as much as I've gotten some day.

NIL ILLEGITIMUS CARBORUNDUM

Phil aka Art
"Vanessa"
1995 VN 750 (bought as 2nd owner 11/2008)
26,440 miles
MF Battery
Stator replaced (55 Days!)
V&H Cruisers
Relocate rear turn signals
Highwayman Saddlemen bags
Wingerline Highway bars
Ear Shave
Rejet carbs
R/R relocate
Coastered
Kuryakin ISO Duallys all around
HD Heritage seat
12" ape hangers

To Do:
Some sort of new grips
Mirrors
Paint Job- should I do it myself?
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post #10 of 10 (permalink) Old 01-24-2010, 07:41 PM Thread Starter
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WOW WOW WOW!!

She's back on the road and purring like a kitten! I got everything back together with nothing more than minor issues along the way. Got the opportunity to do about 150 miles yesterday and I can't tell you how good it felt to be in the wind after having her all torn apart just a short time ago.

I want to say thanks to lance328 specifically for the hours of phone guidance and talking me through all the snags I hit along the way. You're a knowledgeable man who seems more than willing to help others, and turning out to be a good guy to know in general. I wish you were closer so I could buy you a beer

This forum has been a wonderful resource for me and Vanessa. I really didn't know jack about mechanics before I found this site. Honestly, I don't consider myself even proficient yet, but definitely more comfortable turning a wrench on my bike now than I was before. Good people with a common interest and willing to share their experiences.. makes the down time much more bearable.

Thanks again!

NIL ILLEGITIMUS CARBORUNDUM

Phil aka Art
"Vanessa"
1995 VN 750 (bought as 2nd owner 11/2008)
26,440 miles
MF Battery
Stator replaced (55 Days!)
V&H Cruisers
Relocate rear turn signals
Highwayman Saddlemen bags
Wingerline Highway bars
Ear Shave
Rejet carbs
R/R relocate
Coastered
Kuryakin ISO Duallys all around
HD Heritage seat
12" ape hangers

To Do:
Some sort of new grips
Mirrors
Paint Job- should I do it myself?
artemis_f0wl is offline  
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