engine out, waiting on stator - 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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post #1 of 22 (permalink) Old 08-16-2014, 02:43 AM Thread Starter
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engine out, waiting on stator

Much easier that I thought. Once everything was removed it just popped right out. As soon as the TPE stator and all the parts I ordered from ccp.com get here, it should be back together in a few days.


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 #2 of 22 (permalink) Old 08-16-2014, 09:41 AM
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Thanks for the pictures and updates along the way. It seems that everyone always adds another few tips that helps out when doing this.

For me, the more times I see this done the more confident I become for doing this when my 750 eventually needs it.

1996 VN 750
2007 Vulcan Mean Streak SE

When I was younger I was afraid I'd die riding. Now that I'm old and falling apart, I'm afraid I won't.
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post #3 of 22 (permalink) Old 08-16-2014, 12:59 PM
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Did you leave the bevel in place and just disconnect at the final drive?

'04 Vulcan 750 27k+
My first ride- June 2013 @ 22k miles
Stator replaced 27k

"It is the mark of an educated mind to be able to entertain a thought without accepting it." - Aristotle.

"I have never let my schooling interfere with my education"- Mark Twain.
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post #4 of 22 (permalink) Old 08-16-2014, 06:47 PM Thread Starter
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Quote:
Originally Posted by kyledk View Post
Did you leave the bevel in place and just disconnect at the final drive?
Yeah, I left all the final drive parts in place, when I slid the engine forward the engine output shaft on the bevel gear case slipped right out of the U joint. It is a tight fit, because of the shift shaft. You have to slide the engine almost straight forward to get it out of the lower rear mounts, and just before it clears the mounts, start turning it to the right so the shift shaft will clear the frame. I unbolted the front coil and the bracket that holds the wiring harness connectors so I could get the airbox up high enough. I used bungee cords hooked to the handlebars to keep it pulled up out of the way. I used a 1 gallon paint bucket with a couple of magazines on top of it under the engine, and just slid it out from under the bike on that. I have a wooden dolly with casters I built a long time ago to remove VW engines with, I'm going to remodel that a bit to reinstall the engine with. I'm designing it so I can use tapered wooden shims between the engine and the dolly to line up the engine mounts perfectly. A transmission jack would be great, but mine broke a long time ago.

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 #5 of 22 (permalink) Old 08-16-2014, 11:30 PM
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I had someone help me for the engine mounting brackets, lined up and slid the rods into place one at a time with the aid of the jack, so I'm very interested in the "do it yourself" way of it. Post pictures of that dolly if you would!

also, do you anticipate issues putting the engine back in place, having to line up the splines on the bevel and U-joint while putting in the mounting rods? Doing it your way woulda saved me about 2 hours I think...

'04 Vulcan 750 27k+
My first ride- June 2013 @ 22k miles
Stator replaced 27k

"It is the mark of an educated mind to be able to entertain a thought without accepting it." - Aristotle.

"I have never let my schooling interfere with my education"- Mark Twain.
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post #6 of 22 (permalink) Old 08-18-2014, 07:02 PM
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Hey Jerry, how many miles on the scoot when the stator crapped out.

Gordon

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

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July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


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post #7 of 22 (permalink) Old 08-19-2014, 01:43 AM Thread Starter
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Quote:
Originally Posted by OlHossCanada View Post
Hey Jerry, how many miles on the scoot when the stator crapped out.
91,827. That number almost made me decide not to fix it, considering all the work involved. But it was still running fine, it's still too hot outside to enjoy riding much, and I am working on it in my air conditioned house. Or rather it is just sitting right now, waiting on the stator. I already got all the other parts.

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 #8 of 22 (permalink) Old 12-15-2014, 08:00 PM Thread Starter
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Haven't been around in a while, because the Vulcan is still in pieces in my living room. I have the engine finished and back together, but then riding season arrived, and I quit work on it to go ride, since I have several other bikes. We have such a short riding season here I didn't want to waste any of it. I already have close to 8,000 miles on my Royal Enfield with almost no problems. I plan to wait until it gets hot again to finish the Vulcan, since I can work on it in my air conditioned living room when it is 120 degrees out. It will be too hot to do much outside, so I will have bikes to work on inside.

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
VN750Rider/Jerry is offline  
post #9 of 22 (permalink) Old 10-23-2015, 03:50 AM Thread Starter
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Well I finally got the Vulcan all put back together, including the stock intake system. It fired right up after sitting well over a year. I had kept the carbs full of Seafoam the whole time. And it is charging! After cleaning the cobwebs off of it I took it for a ride. Just as comfortable as I remember, but a lot more boring. Don't know if I will keep it or not. While it was took apart, I bought a new Royal Enfield, which now has almost 6000 miles on it, and it is way more fun. Lots of noise and vibration, and it looks beautiful. I quit spending a lot of time cleaning and polishing bikes a long time ago, and just maintained and rode them. But after getting the RE, I found myself doing it again. The Vulcan 750 is a great long distance touring bike. But my health issues now prevent that type of riding. I'll probably go ahead and run it up to 100,000 miles, then think about selling it.
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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
VN750Rider/Jerry is offline  
post #10 of 22 (permalink) Old 10-23-2015, 09:57 PM
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so uou are going to ride the vulcan until it rolls the odometer back to all zeros and sell it for a higher price to someone thinking its a low mileage bike? not exactly a nice thing to do but it is a good idea lol

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