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Join Date: Nov 2007
Location: Chandler, Arizona
Yes, you definitely need a new float. That one has sprung a leak and sunk. I hope you decide not to do the earshave thing, it's a neat idea, and simplifies things considerably, and I like simple. And the Vulcan's intake system is a convoluted nightmare. But I still have to recommend against the earshave if you plan to keep the bike a long time (I have 70,000 miles on mine, and plan to wear it out) because when you do the earshave you have to use air filters that do not filter as well as the stock filters, letting dirt enter the engine, and shortening it's life. I want as many miles as I can get, plus I actually like the ears.
The carbs are not THAT difficult to remove and reinstall, I have done it 3 times total on 2 different Vulcan 750s. Remove everything that can possibly get in the way, and definitely the tank. Remove the 2 rubber ducks, er, ducts, between the surge tank and carbs. If you still have the air injection system installed, now would definitely be a good time to remove that. Removing that does NOT harm the engine. It does require plugging the hole in the surge tank where the hose from the 3 way valve under the seat goes.
Anyway, with the tank out of the way, and the ducts removed, wrap something around the surge tank and the frame backbone tube, and tie it up out of the way, so it won't keep falling down (yes, Kawasaki should have made it removable without pulling the engine, but then there are a LOT of things they should have done differently on this bike that they didn't) Once you have the surge tank tied up out of the way, disconnect everything from the carbs EXCEPT the throttle cables, loosen the manifold clamps, spray lots of WD-40 between the manifolds and carbs, and slowly and carefully work them out the right side. Since you already have them out, you are halfway there. They go back the same way, get everything out of the way, tie up the surge tank, and soak the manifolds and carb outlets in WD. They will slip into place fairly easily. There is almost no maneuvering room, but they will fit. Patience is the key here, as they will fit only one way. The WD makes them slip right into the manifolds when you get them lined up just right. It will be a tight fit, as they will not want to line up with both manifolds at once. Again, there is where the WD-40 comes in real handy.
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