Rusty Valves - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 16 (permalink) Old 04-12-2011, 12:14 PM Thread Starter
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Rusty Valves

I have an engine that has been out of the bike for a long time. I pulled the rags out of the intake boots the previous owner had placed there. I assumed they were placed there after the engine had been removed, but it was likely an afterthought as the intake valves are very rusty.

I'm going to pull the heads off and clean them up the best I can. I'm just wondering how far I should go since I have the engine out and apart.

Should I just do the valves and put it back together with new head gaskets? Or should I pull the cylinders off and check the piston and rings while I'm at it?

It should be noted that the bike has low Kms.

Street
1985 VN750 Acquired Feb, 2011 - 13,676km
Mods - Ear Shave, Pickup Coil Gap, Drilled Clutch Basket, Shift Tie Rod, Mosfet R/R, MF Battery, De-Goated (H-Pipe), MCCT, Heated Grips, Plexistar 2 Windshield

Dirt
2004 KTM SX 125 - 1979 Can-Am Qualifier 250 - 1971 Kawasaki F6

Video Tutorials - Engine Rebuild - Fork Seal Replacement - Grease Swing Arm Bearings - Carb Rebuild - Spline Lube - Refilling Rear Shocks - Grease Steering Bearings
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post #2 of 16 (permalink) Old 04-12-2011, 02:41 PM
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Yes check the whole works,the cylinders and rings are most likely the same. A lot of moisture was allowed into the engine. I would also take a good look at the stator through the small cover on the left side of engine. If it is burnt and discolored it is shot and also check the stator wires.You can also do a stator grounding check. Have fun and try to check everything, no fun trying to pull it out again if there are other problems.

2004 25,500 miles
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post #3 of 16 (permalink) Old 04-12-2011, 04:28 PM Thread Starter
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Yeah that's what I figured. If the valve are rusty, everything probably is. I guess I was trying to justify not doing so much work.

Oh well, it'll be a learning experience.

I'll check the stator as mentioned.

Is there any good resources for VN engine rebuilds? I did a quick search on here and Google, didn't come up with anything specific to Vulcans.

Street
1985 VN750 Acquired Feb, 2011 - 13,676km
Mods - Ear Shave, Pickup Coil Gap, Drilled Clutch Basket, Shift Tie Rod, Mosfet R/R, MF Battery, De-Goated (H-Pipe), MCCT, Heated Grips, Plexistar 2 Windshield

Dirt
2004 KTM SX 125 - 1979 Can-Am Qualifier 250 - 1971 Kawasaki F6

Video Tutorials - Engine Rebuild - Fork Seal Replacement - Grease Swing Arm Bearings - Carb Rebuild - Spline Lube - Refilling Rear Shocks - Grease Steering Bearings
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post #4 of 16 (permalink) Old 04-12-2011, 07:30 PM
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jthill has a couple of threads on his rebuild. Lots of pictures and very helpful. Can't remember the title right now. There is an internal shift rod on the early models that was poorly designed. That should be replaced with the improved version that won't break. I'd also replace the balance dampers as they are probably bad as well. Go ahead and do the stator mod that allows you to replace it without pulling the engine (for next time),

I'm keepin' all the left over parts. I'm gonna use 'em to build another bike!
_____________________________________________
"Black Beauty"
1989 VN750 acquired December, 2008, 6,711 miles
Currently 23,298 miles

Old Blue
2001 Honda CMX250 Rebel acquired July, 2008

1987 VN750 project bike, acquired August, 2009, 33,000 miles and balancer sticking out of the case, currently awaiting attention and parts
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post #5 of 16 (permalink) Old 04-12-2011, 09:47 PM Thread Starter
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I think I found those threads.
Thread 1
Thread 2

Wow, these will be very helpful.

If the crank looks good when I pull the cylinders off I'll probably leave the bottom end alone.

I think I'll also make YouTube videos of the entire process.

Street
1985 VN750 Acquired Feb, 2011 - 13,676km
Mods - Ear Shave, Pickup Coil Gap, Drilled Clutch Basket, Shift Tie Rod, Mosfet R/R, MF Battery, De-Goated (H-Pipe), MCCT, Heated Grips, Plexistar 2 Windshield

Dirt
2004 KTM SX 125 - 1979 Can-Am Qualifier 250 - 1971 Kawasaki F6

Video Tutorials - Engine Rebuild - Fork Seal Replacement - Grease Swing Arm Bearings - Carb Rebuild - Spline Lube - Refilling Rear Shocks - Grease Steering Bearings
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post #6 of 16 (permalink) Old 04-13-2011, 09:39 AM
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I'm just going by what our late VN7XX guru, lance said. The internal shift rod will break at some point, and need to be replaced. The balance dampers on the early model bikes, especially if they sat for extended periods, as it appears yours may have, deteriorate. If they go, the balancer will eventually come out the lower end, resulting in serious damage. See the 1987 project bike in my sig.

Your choice.

I'm keepin' all the left over parts. I'm gonna use 'em to build another bike!
_____________________________________________
"Black Beauty"
1989 VN750 acquired December, 2008, 6,711 miles
Currently 23,298 miles

Old Blue
2001 Honda CMX250 Rebel acquired July, 2008

1987 VN750 project bike, acquired August, 2009, 33,000 miles and balancer sticking out of the case, currently awaiting attention and parts
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post #7 of 16 (permalink) Old 04-13-2011, 10:34 AM
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Quote:
Originally Posted by Roach View Post
I think I found those threads.
Thread 1
Thread 2

Wow, these will be very helpful.

If the crank looks good when I pull the cylinders off I'll probably leave the bottom end alone.

I think I'll also make YouTube videos of the entire process.
There is a third thread too - The journey ending:
https://www.vn750.com/forum/showthread.php?t=11063

Gordon

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

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/11-vn750-general-discussion/9127-top-ten-items-you-would-suggest-new-owner-do-his-new-ride.html
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post #8 of 16 (permalink) Old 04-13-2011, 10:45 AM
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Quote:
Originally Posted by flitecontrol View Post
jthill has a couple of threads on his rebuild. Lots of pictures and very helpful. Can't remember the title right now. There is an internal shift rod on the early models that was poorly designed. That should be replaced with the improved version that won't break. I'd also replace the balance dampers as they are probably bad as well. Go ahead and do the stator mod that allows you to replace it without pulling the engine (for next time),
X2- Change out the shifter tie-rod for the stronger one while the engine is already out of the frame.

Same for the balancer dampers, and inspect the stator too.
You are 90% of the way there, so fix it right now and you won`t be pulling the engine again in a year or two.

Gordon

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

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/showthread.php?t=9127
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post #9 of 16 (permalink) Old 04-13-2011, 12:49 PM Thread Starter
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Quote:
Originally Posted by flitecontrol View Post
I'm just going by what our late VN7XX guru, lance said. The internal shift rod will break at some point, and need to be replaced. The balance dampers on the early model bikes, especially if they sat for extended periods, as it appears yours may have, deteriorate. If they go, the balancer will eventually come out the lower end, resulting in serious damage. See the 1987 project bike in my sig.

Your choice.
Quote:
Originally Posted by OlHossCanada
X2- Change out the shifter tie-rod for the stronger one while the engine is already out of the frame.

Same for the balancer dampers, and inspect the stator too.
You are 90% of the way there, so fix it right now and you won`t be pulling the engine again in a year or two.

OK, you guys are right. Might as well do it properly the first time. I was trying to cut corners because it is getting nice out and all my friends are firing up their bikes.

I think I read on here that there are no gasket kits available? The best bet is to order them one by one from BikeBandit?

So if I order a newer model shifter tie-rod it'll fit without issue? How much newer?

Street
1985 VN750 Acquired Feb, 2011 - 13,676km
Mods - Ear Shave, Pickup Coil Gap, Drilled Clutch Basket, Shift Tie Rod, Mosfet R/R, MF Battery, De-Goated (H-Pipe), MCCT, Heated Grips, Plexistar 2 Windshield

Dirt
2004 KTM SX 125 - 1979 Can-Am Qualifier 250 - 1971 Kawasaki F6

Video Tutorials - Engine Rebuild - Fork Seal Replacement - Grease Swing Arm Bearings - Carb Rebuild - Spline Lube - Refilling Rear Shocks - Grease Steering Bearings
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post #10 of 16 (permalink) Old 04-13-2011, 01:15 PM
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Quote:
Originally Posted by Roach View Post
OK, you guys are right. Might as well do it properly the first time. I was trying to cut corners because it is getting nice out and all my friends are firing up their bikes.

I think I read on here that there are no gasket kits available? The best bet is to order them one by one from BikeBandit?

So if I order a newer model shifter tie-rod it'll fit without issue? How much newer?
Yes, I believe you have to order all the gaskets individually.

To the best of my knowledge, the old tie-rod has been superceded by a new part number since some time in the 90`s.
The old part should not even be in stock anymore.

http://www.indyoem.com/fiche_section...1991&fveh=9040
P/N 39110 on this diagram, but does not indicate a superceded number like some others on this site. ($4.80)

Bike Bandit has the same diagram with number 39110, but the parts list has an entirely different p/n??
Still not a supeceded number shown though?? ($7.50)
http://www.bikebandit.com/houseofmot...m4555#sch51723

Email or phone the supplier to confirm you are ordering the new heavy duty tie rod.

Gordon

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

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/showthread.php?t=9127

Last edited by OlHossCanada; 04-13-2011 at 01:54 PM.
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