Tuxedo - Template for Hole Saw - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Electrical
Where does this wire go?
Includes Electrical mods, Lights, Stator,
Rectifier, Diagrams, etc

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  • 2 Post By T-Bone
  • 1 Post By mmart
 
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post #1 of 9 (permalink) Old 05-18-2019, 09:37 AM Thread Starter
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Tuxedo - Template for Hole Saw

My stator died (19k miles) so I decided to try the Tuxedo mod using a 4.25 hole saw to cut through the case. Since a pilot hole was not possible, I created a jig to hold the bit in place and keep it from jumping around. I used plexi because I had it around and it made it easy to line up the holes. I used M6-1, one inch bolts and half-inch spacers to fix the jig about a half inch off the case for better stability. I ran it in reverse for a while until I had a nice groove but got impatient (my primary character flaw) and ran it forward. I used plenty of cutting oil. It worked very well.

https://www.vn750.com/photopost/show...o=6223&cat=500

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https://www.vn750.com/photopost/show...o=6219&cat=500

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ubertalldude and roadpouring like this.

Last edited by T-Bone; 05-18-2019 at 09:54 AM.
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post #2 of 9 (permalink) Old 05-18-2019, 10:57 AM
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Nice work! Got to be one of the cleanest cuts I've seen on a tux mod, besides maybe one done on a mill.

And now you can sell those jigs.

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post #3 of 9 (permalink) Old 05-19-2019, 10:16 AM Thread Starter
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Thank you!
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post #4 of 9 (permalink) Old 05-19-2019, 12:23 PM
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Smart thinking, this is way cleaner than using a dremel. I presume the cutting oil captured most of the chips, right?

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post #5 of 9 (permalink) Old 05-20-2019, 11:48 AM Thread Starter
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Yes. Most of the chips were in the goop but some still got in when the saw cut through. I took out the stator and sprayed down everything I could reach with Kerosene. Then I replaced the cover and flushed kero through the oil cap six or seven times, straining the kerosene through disposable shop towels and reusing. After it came through clean I put the drain cover in, poured in a gallon of kerosene and rocked the bike around - side to side and like a rocking horse, and then drained and repeated another six times. When I was done putting in the new stator I put in oil, leaving the old filter, and ran it for a while. Tonight I'm going to warm it up and do an oil change with a new filter.
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post #6 of 9 (permalink) Old 05-20-2019, 11:54 AM
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Great work!

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post #7 of 9 (permalink) Old 05-20-2019, 12:56 PM
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I’ve been following both threads about that jig you built. Great thinking there. What puzzles me is why the stator is “trapped” where it is in the first place. I mean I understand the electrical principles involved as to why its located there, but why didn’t they engineer it with a removable plate? If we can figure out a way to open it up, why couldn’t they? My 2 cents 😁
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post #8 of 9 (permalink) Old 05-20-2019, 03:40 PM
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It's just a bad design....we aren't sure why. Oddly the right side of the frame has a removable member, opposite the stator, so my theory is originally, the two were supposed to be on the same side and someone basically Fukked up.

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post #9 of 9 (permalink) Old 05-20-2019, 03:58 PM
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Ha I can’t argue against that theory, smart people make the dumbest mistakes usually. The guy designing the engine never walked over to the guy designing the frame to make sure they were on the same page. **** happens, but why not correct it over the 21 yrs of production. Head scratcher...
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