tackled the engine pull today - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 20 (permalink) Old 03-24-2007, 06:31 PM Thread Starter
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tackled the engine pull today

successfully pulled the engine today with the help of a friend. it took us about five hours of work... fairly straightforward with the help of the clymer manual. wrangling the engine over to the right took some effort, but we eventually got it over. i'm sending my engine cover to toc to have them machine the easy removal mod. justice should be back on the road in no time. i'm excited.
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post #2 of 20 (permalink) Old 03-24-2007, 11:06 PM
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i bet your glad you are doing that huh? i know before i pulled mine i thought the money was too much. After the pull i said it was worth it and called them up

'04 Vn750
Currently Installed
nat'l cycle deflector shield
westco 12v30 MF, 30A/h w/ 350 CCA's w/ custom box
TOC stator cover w/ Frankenstator mod!
R/R relo

Soon to have (own or on order)
TOC ACCT's
Mez's 110-FRT 170/80-Rear
Custom rear fender and tail light
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post #3 of 20 (permalink) Old 03-25-2007, 03:07 PM Thread Starter
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Quote:
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i bet your glad you are doing that huh? i know before i pulled mine i thought the money was too much. After the pull i said it was worth it and called them up
my friend is a fairly accomplished mechanic; i'm not sure i would have felt comfortable without his help... and i'm certain there's no way i would have gotten the engine physically out of the frame without him. i just couldn't justify giving all that money to a shop for labor costs; this was really my only option. glad i did it. now... the trick will be putting everything back together after i get the toc modded cover.

paul
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post #4 of 20 (permalink) Old 03-26-2007, 12:50 AM
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Quote:
Originally Posted by global_recon View Post
my friend is a fairly accomplished mechanic; i'm not sure i would have felt comfortable without his help... and i'm certain there's no way i would have gotten the engine physically out of the frame without him. i just couldn't justify giving all that money to a shop for labor costs; this was really my only option. glad i did it. now... the trick will be putting everything back together after i get the toc modded cover.
Once you swing the engine back into the frame, i found it was easiest to do the first mount first, then the top, and then the back. Keep them loose until the bolts are threw all 3. After that, man assembley goes quick.... make sure you also use antiseze and all the bolts on the engine, aluminum and steel dont mix otherwise. Also make sure you get all new gaskets including the bevel gear case. If you want i've already got the part numbers here. Just PM me and i'll save you the trouble of searching microfech.

'04 Vn750
Currently Installed
nat'l cycle deflector shield
westco 12v30 MF, 30A/h w/ 350 CCA's w/ custom box
TOC stator cover w/ Frankenstator mod!
R/R relo

Soon to have (own or on order)
TOC ACCT's
Mez's 110-FRT 170/80-Rear
Custom rear fender and tail light
Givi hard bags w/ custom rear turn signals


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post #5 of 20 (permalink) Old 03-26-2007, 09:17 AM
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Two things on re-assembling..
The hardest and most frustrating was getting the front bevel gear in place and connected to the swingarm.
And after re-assembling and turning the key we heard crank, crank THUD..
the pickup coils had been reversed in the stator casing throwing the timing off 90/270.. so the round cover came off and they were switched back and she fired right up.

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post #6 of 20 (permalink) Old 03-26-2007, 09:38 AM
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Quote:
Originally Posted by Dianna View Post
Two things on re-assembling..
The hardest and most frustrating was getting the front bevel gear in place and connected to the swingarm.
And after re-assembling and turning the key we heard crank, crank THUD..
the pickup coils had been reversed in the stator casing throwing the timing off 90/270.. so the round cover came off and they were switched back and she fired right up.
I found it easier to pull off the rear wheel, pull off the rear and release the pressure on the bevel gear. A little more dissassembly, but made the job MUCH easier. Plus, throw some grease on the splines while its out.

Jon

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post #7 of 20 (permalink) Old 03-26-2007, 07:05 PM
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Quote:
Originally Posted by 93VN750 View Post
I found it easier to pull off the rear wheel, pull off the rear and release the pressure on the bevel gear. A little more dissassembly, but made the job MUCH easier. Plus, throw some grease on the splines while its out.

Jon
same here... once the back wheel was off, the hardest part was remembering which bolt went in which hole...This time i am labeling every part with some masking tape and a marker.

'04 Vn750
Currently Installed
nat'l cycle deflector shield
westco 12v30 MF, 30A/h w/ 350 CCA's w/ custom box
TOC stator cover w/ Frankenstator mod!
R/R relo

Soon to have (own or on order)
TOC ACCT's
Mez's 110-FRT 170/80-Rear
Custom rear fender and tail light
Givi hard bags w/ custom rear turn signals


Band Engineer/Webmaster for Josey Contreras Tejano Band
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post #8 of 20 (permalink) Old 03-27-2007, 08:49 PM
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I use a plano tackle box with the partitions numbered. Then I just use a notebook to note what went into that numbered spot. The tackle box is sealable, and I have plenty on hand as fishing is another of my passtimes.

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post #9 of 20 (permalink) Old 04-17-2007, 04:33 PM Thread Starter
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going to attempt the reassembly this saturday. my new stator arrived from rick's last week, front bevel gear case and engine cover gaskets should be arriving from ron ayers on thursday and i just picked up my toc modded engine cover from the post office today. incidentally, i'd like to throw in a good word for toc manufacturing... they said they generally shoot for a same or next day turnaround after receiving the engine cover, but there was a delay with my cover due to a couple of unforeseeable factors. they threw in a set of ACCT springs and stator hex bolts at no charge. seems like a great bunch of guys at the company.

anyway, hope everything goes smoothly on saturday. really excited to get justice back on the road.

paul
1991 vn750: 'for great justice'
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post #10 of 20 (permalink) Old 04-17-2007, 04:43 PM
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A little tip on the engine install that worked for me...Take your front and rear wheel off, sit the engine on the floor and lift the frame of the bike over the engine, then install the bolts. It'll take a bout 20 min to do. Then I used a hoist to pick the bike back up on to the lift.

Just thought I'd share......

'92 Vn750

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