Tuxedo Mod Tips - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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Where does this wire go?
Includes Electrical mods, Lights, Stator,
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post #1 of 14 (permalink) Old 05-02-2020, 03:47 PM Thread Starter
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Tuxedo Mod Tips

While my engine is out for rebuild, I am doing the tuxedo mod! The plate as is has ribs offset from the mounting holes. If you tighten the screws down, the new plate will warp. I used JB Weld to glue 2 grade #8 3/8 washers to the plate to provide the same spacing as the ribs. It now is solid and straight when I tighten everything down (pictures 1-3, 3 showing warp).

I also ground off the heads of some longer bolts, to align everything during assembly (picture 4). I leave two in and screw in the third screw. Then I remove one and add another cover screw, and onto the last one.

Lastly (also picture 4, upper left screw) I have some short screws so I can run the engine with the cover off (for timing adjustments).

I did NOT yet cut the notch in my outer cover, since I am still using the original stator. However, if it fails, I can cut the wires and notch at that time.
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roadpouring likes this.


'89 VN750 Bought stock 4/12/18 @ 17805.9 miles $800. Wrecked once. 27454.5+ miles

Completed modifications:
Removed mufflers, straight pipes out of GB. 110/90 Front Tire. Pick-up coil mod. Shindengen MOSFET FH020AA r/r. USB Outlet + Voltmeter. Repainted Metallic Blue w/ new tank bages. Ear Shave (wo/ coasters) 40/140 NO shims 45MPG. MCCT conversion.

Planned modifications:
Custom LED turn signals. Windshield. Highway Pegs. (Possible) ignition adv. Tuxedo Mod. Ignition coil mod.
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post #2 of 14 (permalink) Old 05-02-2020, 03:51 PM
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Looks like a clean job, nice work!

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
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post #3 of 14 (permalink) Old 05-02-2020, 07:50 PM Thread Starter
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Well, I'm not getting the outer cover to go on. I ground off the ribs as instructed, but the three mounting holes are hitting the plate, leaving a gap. I ground down the inward side of the mounting holes until they are level with the ribs, but still it doesn't fit. I don't want to grind more until I know if I am even doing the right thing.

How thick is the new plate supposed to be? I didn't see any dimensions in the video or the Facebook link. Mine is 1/8" thick.

The video shows an almost sloppy amount of silicone gasket. I can't imagine he left a gap the whole way around!

The silicone in the screw holes implies that he didn't use the O rings on the screws.


'89 VN750 Bought stock 4/12/18 @ 17805.9 miles $800. Wrecked once. 27454.5+ miles

Completed modifications:
Removed mufflers, straight pipes out of GB. 110/90 Front Tire. Pick-up coil mod. Shindengen MOSFET FH020AA r/r. USB Outlet + Voltmeter. Repainted Metallic Blue w/ new tank bages. Ear Shave (wo/ coasters) 40/140 NO shims 45MPG. MCCT conversion.

Planned modifications:
Custom LED turn signals. Windshield. Highway Pegs. (Possible) ignition adv. Tuxedo Mod. Ignition coil mod.
Jason Pittenger is online now  
 
post #4 of 14 (permalink) Old 05-02-2020, 07:54 PM Thread Starter
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Quote:
Originally Posted by Spockster View Post
Looks like a clean job, nice work!
Thanks!

And I went back to the original post about the mod, and it says 16 gauge (or 1/16"). I might have to do a new plate...


'89 VN750 Bought stock 4/12/18 @ 17805.9 miles $800. Wrecked once. 27454.5+ miles

Completed modifications:
Removed mufflers, straight pipes out of GB. 110/90 Front Tire. Pick-up coil mod. Shindengen MOSFET FH020AA r/r. USB Outlet + Voltmeter. Repainted Metallic Blue w/ new tank bages. Ear Shave (wo/ coasters) 40/140 NO shims 45MPG. MCCT conversion.

Planned modifications:
Custom LED turn signals. Windshield. Highway Pegs. (Possible) ignition adv. Tuxedo Mod. Ignition coil mod.
Jason Pittenger is online now  
post #5 of 14 (permalink) Old 05-02-2020, 08:47 PM
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Looks like a really nice job
I thought I saw a video somewhere , they made their own gasket (1/16” or 1/8 thick ?) to move the cover outward enough to be tight before bottoming out. ? Just a thought if I understand problem correctly.

Grumpy Old Man

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post #6 of 14 (permalink) Old 05-02-2020, 11:13 PM Thread Starter
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I read through about 11 pages of the sticky thread, and apparently the mod requires making your own gasket.

However, after the grinding I did, I'm left with a 1/16" gap.
That means if I change me 1/8" plate out for a 1/16" plate, I should be able to use the factory gasket and o-rings again!


'89 VN750 Bought stock 4/12/18 @ 17805.9 miles $800. Wrecked once. 27454.5+ miles

Completed modifications:
Removed mufflers, straight pipes out of GB. 110/90 Front Tire. Pick-up coil mod. Shindengen MOSFET FH020AA r/r. USB Outlet + Voltmeter. Repainted Metallic Blue w/ new tank bages. Ear Shave (wo/ coasters) 40/140 NO shims 45MPG. MCCT conversion.

Planned modifications:
Custom LED turn signals. Windshield. Highway Pegs. (Possible) ignition adv. Tuxedo Mod. Ignition coil mod.
Jason Pittenger is online now  
post #7 of 14 (permalink) Old 05-02-2020, 11:23 PM
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Quote:
Originally Posted by Jason Pittenger View Post
I read through about 11 pages of the sticky thread, and apparently the mod requires making your own gasket.

However, after the grinding I did, I'm left with a 1/16" gap.
That means if I change me 1/8" plate out for a 1/16" plate, I should be able to use the factory gasket and o-rings again!
That was a good part of the reason I avoided that mod. Kluged gaskets usually end up leaking, especially if I kluge it.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
Spockster is offline  
post #8 of 14 (permalink) Old 05-09-2020, 02:10 PM
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Quote:
Originally Posted by Jason Pittenger View Post
I read through about 11 pages of the sticky thread, and apparently the mod requires making your own gasket.

However, after the grinding I did, I'm left with a 1/16" gap.
That means if I change me 1/8" plate out for a 1/16" plate, I should be able to use the factory gasket and o-rings again!
This looks like a good tip to fixing the gasket gap problem. Should post it to the best plate mod thread and/or get it in a sticky post.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
Spockster is offline  
post #9 of 14 (permalink) Old 05-09-2020, 03:52 PM Thread Starter
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Once I get the parts back, I'll verify that it works and, I'll post more pictures.


'89 VN750 Bought stock 4/12/18 @ 17805.9 miles $800. Wrecked once. 27454.5+ miles

Completed modifications:
Removed mufflers, straight pipes out of GB. 110/90 Front Tire. Pick-up coil mod. Shindengen MOSFET FH020AA r/r. USB Outlet + Voltmeter. Repainted Metallic Blue w/ new tank bages. Ear Shave (wo/ coasters) 40/140 NO shims 45MPG. MCCT conversion.

Planned modifications:
Custom LED turn signals. Windshield. Highway Pegs. (Possible) ignition adv. Tuxedo Mod. Ignition coil mod.
Jason Pittenger is online now  
post #10 of 14 (permalink) Old 05-24-2020, 08:22 AM Thread Starter
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After 3 attempts, I have a tuxedo mod that uses the factory gaskets with no gaps!

It took a lot of ingenuity from my friend to get this to work. The plate is held to the original housing by 4 set screws. These screws are in 4 tapped holes added to the original side housing.

In the top left, there is a small pin hole (1/16). There is a second near the bottom (3/32) but hard to see. These are alignment holes. The stator was wrapped with thin cardboard (beer can box) and put in place. I drilled both of these holes through the plate into the side housing, to mark the position. Then I assembles it on the table and put it back in.

The other beauty of this method is now the stator is held by the side housing instead of the outer cover. You can pull the outer cover off without removing the stator. Convenient for the coil mod, or checking the timing, or in my case, aftermarket ignition planned for sometime in the future.

The stator wires still go through the original hole in the original housing. Replacing the stator, will require a cut in the outer cover for the wires.
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roadpouring likes this.


'89 VN750 Bought stock 4/12/18 @ 17805.9 miles $800. Wrecked once. 27454.5+ miles

Completed modifications:
Removed mufflers, straight pipes out of GB. 110/90 Front Tire. Pick-up coil mod. Shindengen MOSFET FH020AA r/r. USB Outlet + Voltmeter. Repainted Metallic Blue w/ new tank bages. Ear Shave (wo/ coasters) 40/140 NO shims 45MPG. MCCT conversion.

Planned modifications:
Custom LED turn signals. Windshield. Highway Pegs. (Possible) ignition adv. Tuxedo Mod. Ignition coil mod.
Jason Pittenger is online now  
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