When is a 750 a 1500? (Winter Project) - Page 3 - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #21 of 26 (permalink) Old 01-23-2015, 11:44 AM Thread Starter
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Okay, this is messed up!!

I was working on the bike last night, and hooking things back up... I connected the breather and vac tubes to the surge tank (air box) just like on the VN750... haven't put the ears back on yet since I'm waiting on new Ermgo filters to arrive... I thought I'd just crank the engine to make sure everything was still running okay, and when I cranked it (it was hard to start), all of a sudden fuel started pouring out the bottom of the bike!!

I shut it off immediately, and tried to find the source of fuel leak... everything was dry around the fuel tank, fuel tank vent, petcock, fuel pump, fuel lines, and carb... it seemed that the fuel was coming from somewhere midway up between the rear cylinder and the battery box... the only thing there that could even remotely connect to fuel system is the emissions control vacuum valve canister thingie... It was wet with fuel on the outside, and fuel was dripping down and off the bottom of the frame and engine/goats belly...

The only thing I did differently than the other day was connect the two tubes to the front of the airbox behind where the ears mount... The left one is the crankcase breather, so that can't be the culprit, and the other is a vac line going to the carb I think...

I've checked the manual, and as far as I can tell all the hoses are connected correctly on the carb, and everything is where it's supposed to be...

What in the world could cause fuel to pour out of the emissions vacuum canister!?

I don't totally understand the vacuum system, if one of the ports off the surge tank is blocked, could that cause a vacuum loop, and make the emissions vac suck gas out of the carb??

------------------------------
GloryRider
Atlanta, GA
Current Ride: 1995 Vulcan 88 (1500A9)
Purchased Dec. 2014
approx. 6,800 miles

Previous Bike: 2000 VN750 "Glory"
With homemade stator
Details on stator build here

"Four wheels move the body. Two wheels move the soul"

"You live more in 5 minutes on a bike like this going flat out than some people live in their lifetime." - Burt Munro

Last edited by GloryRider; 01-23-2015 at 11:47 AM.
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post #22 of 26 (permalink) Old 01-26-2015, 11:13 AM Thread Starter
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In case anyone is interested, lol...

I figured out what happened... it was a stuck float needle!

I took the carbs back off, and separated them, checked the float needles, and one side was stuck, so it wouldn't close, and that caused the pressure in the system to never rise and shut off the gas pump, so the pump just kept on supplying gas, and it kept filling up the carb, and then overflowing out into every place it could!

Anyways... good to know what it was at least!

Hopefully I can get a new one, and remember how to put this carb back together, lol!

------------------------------
GloryRider
Atlanta, GA
Current Ride: 1995 Vulcan 88 (1500A9)
Purchased Dec. 2014
approx. 6,800 miles

Previous Bike: 2000 VN750 "Glory"
With homemade stator
Details on stator build here

"Four wheels move the body. Two wheels move the soul"

"You live more in 5 minutes on a bike like this going flat out than some people live in their lifetime." - Burt Munro
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post #23 of 26 (permalink) Old 01-26-2015, 04:02 PM
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Wow.that makes sense

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post #24 of 26 (permalink) Old 02-03-2015, 10:44 AM Thread Starter
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Dang this fuel system is giving me nightmares!

I replaced the float needles and cleaned everything out real good... put it all back together, and... it's still dumping gas out of the carb breather tube!!

I figured maybe the fuel pump's pressure check valve might be stuck, and it's just continuing to pump, even after the fuel pressure at the carb inlet is too high, thus overwhelming the float needles and forcing too much gas into the float chamber...

To test, I bypassed the fuel pump, and propped the gas tank up on a ladder to gravity feed directly into the carb... the bike started up, and ran fine, without dumping fuel.

Sooo... I guess it's a fuel pump issue... I tried running the pump dry on input and putting my thumb over the output hose to see if it continued to build pressure, but I can't really tell... I guess I'd need a gauge of some sort to really test it...

------------------------------
GloryRider
Atlanta, GA
Current Ride: 1995 Vulcan 88 (1500A9)
Purchased Dec. 2014
approx. 6,800 miles

Previous Bike: 2000 VN750 "Glory"
With homemade stator
Details on stator build here

"Four wheels move the body. Two wheels move the soul"

"You live more in 5 minutes on a bike like this going flat out than some people live in their lifetime." - Burt Munro
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post #25 of 26 (permalink) Old 02-19-2015, 01:08 PM Thread Starter
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Almost ready to ride!

I've been working hard on this thing, and I'm almost ready to get it on the road... Had to rebuild the forks, seals were completely dry rotted and disintegrated, and forks were half-full of rusty, nasty old oil and water...

I also replaced both tires, mounted and balanced them myself, which was a new experience, but lots of lessons learned!

I got the front end put back together a couple nights ago, so only have the rear to finish up... I'm going to lube the splines while I have the rear wheel off, and then should be good to go!

Here's some pics







------------------------------
GloryRider
Atlanta, GA
Current Ride: 1995 Vulcan 88 (1500A9)
Purchased Dec. 2014
approx. 6,800 miles

Previous Bike: 2000 VN750 "Glory"
With homemade stator
Details on stator build here

"Four wheels move the body. Two wheels move the soul"

"You live more in 5 minutes on a bike like this going flat out than some people live in their lifetime." - Burt Munro
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post #26 of 26 (permalink) Old 02-19-2015, 09:08 PM
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Looks like you're getting there, I take it you resolved the fuel issue? I've always found it kinda odd how much the 1500A looked like the 750. Good luck, it won't be long now




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