VN750 Engine Rebuild Videos - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 109 (permalink) Old 05-11-2011, 12:08 PM Thread Starter
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VN750 Engine Rebuild Videos

I'm tearing apart the engine on my VN750 with the intention of rebuilding it. I'm going to try and document the entire process in a series of YouTube videos.

Thanks to everyone for the tips so far, and please give me a shout if you have any more.

EDIT: I'm going to put all the videos in this first post to make them easier to find.

EDIT 2: I've also created a YouTube Playlist with all the videos

1985 Kawasaki Vulcan Engine Rebuilt Playlist

EDIT 3: I've been asked to note that the procedures in the videos are applicable to all model years from 1985 to 2006 for the Vulcan 700/750.

EDIT 4: Here is a crude spreadsheet with the cost



1985 Kawasaki Vulcan Engine Rebuild

Pt.1 - Removing & Disassembling Heads

Pt.2 - Removing Clutch, Starter Gear, Right Balancer, Right Cam Chains & Sprockets, Rear Cylinder, Stator & Cover

Pt.3 - Removing & Cleaning Valves, Removing HLA oil filter, Cleaning Heads

Pt.4 - Removing Flywheel, Left Balancer, Left Cam Chains & Sprockets, Front Cylinder

Pt.5 - Removing Final Drive, Damper Cam, External Shift Mechanism Cover, Oil Filter Plate

Pt.6 - Removing Pistons, Engine Case Bolts, Splitting Engine Case, Removing Crank Shaft, Transmission, Oil lines,

Pt.7 - Removing Water Pump Shaft, Water Pump Mechanical Seal, Oil Pump Sprocket & Chain, Balancer Shaft, Oil Pump, Left Side Oil Pipe, Oil Pressure Relief Valve, Oil PAssage Cover, Shift Drum, Shift Mechanism, Tie Rod & Shaft

Pt.8 - Bleeding HLAs, Checking Tolerances on Cam Shafts & Cam Shaft Covers

Pt.9 - Checking Tolerance on Heads, Cam Shafts, Cam Chains, HLA Leak Down, Valves, Valve Guides, Valve Seats

Pt.10 - Checking Tolerances on Valve Springs, Cylinders, Pistons, Piston Rings

Pt.11 - Checking Tolerances on Clutch Plates, De-glazing Clutch Plates, Checking Tolerances on Oil Pump

Pt.12 - Checking Tolerances on Crankshaft, Transmission, Honing Cylinders

Pt.13 - Lapping Valves

Pt.14 - Drilling Clutch Hub (Fix Coffee Grinder Noise), Installing Valves

Pt.15 - Installing HLAs, Rocker Arms & Springs

Pt.16 - Installing Oil Pump, Balancer Shaft, Oil Pump Chain & Sprocket, Oil Passage Cover, Oil Relief Valve, Oil Lines

Pt.17 - Installing Internal Shift Mechanism (Tie Rod, Shift Shaft, Shift Arm), Oil Pump Chain Guide, Oil Return Line, Water Pump Mechanical Seal, Water Pump Impeller & Shaft.

Pt.18 - Installing Shift Drum, Gear Position Lever, External Shift Mechanism Cover, Transmission

Pt.19 - Install Crankshaft, Combining Crank Case Halves, Oil Filter Plate, Starter Idler Gear, Right Side Balancer

Pt.20 - Install Left Side Balancer, Flywheel, Pistons,

Pt.21 - Install Cylinders, Cam Chains, Cam Chain Guides

Pt.22 - Install Heads and Spark Plug Retainers

Pt.23 - Installing Cam Shafts, Setting Cam Chain Timing, Installing Cam Cap, Cam Chain Tensioners, and Cam Shaft Cover

Pt.24 - Installing Flywheel, Primary Gear, Pick up coil mod, Shift Shaft Oil Seal, Left Side Engine Cover, Pick Up Coil Gap, External Oil Lines, Oil Pressure Switch

Pt.25 - Installing Clutch, Right Side Engine Cover, Clutch Cover

Pt.26 - Installing the Exhaust manifolds, Oil Drain Plugs, Carburetors, Starter motor, Final Drive Gearbox. Mounting the engine and starting the bike.
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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

Last edited by Roach; 03-13-2014 at 06:11 PM.
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post #2 of 109 (permalink) Old 05-11-2011, 12:31 PM
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This is great. I'm anticipating the finished set of videos.
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post #3 of 109 (permalink) Old 05-13-2011, 11:50 AM Thread Starter
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Edit

Whoops, something went wrong with part 2.

I'll try to re-upload it tonight

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

Last edited by Roach; 05-13-2011 at 11:56 AM.
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post #4 of 109 (permalink) Old 05-13-2011, 04:09 PM
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There is nothing like seeing the job done firsthand, just being a fly on the wall and watching a masterful mechanic take things apart correctly and with explanations. Thanks for a great job on part 1, and I'm anxiously anticipating part 2!
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post #5 of 109 (permalink) Old 05-13-2011, 04:12 PM Thread Starter
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Quote:
masterful mechanic
Hahahaha

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 109 (permalink) Old 05-13-2011, 04:25 PM
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cool man
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post #7 of 109 (permalink) Old 05-13-2011, 04:43 PM
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You must be a master mechanic, my hands never moved that fast removing stuff!

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 #8 of 109 (permalink) Old 05-13-2011, 04:53 PM
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very cool. thanks for doing this

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post #9 of 109 (permalink) Old 05-13-2011, 08:27 PM
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Awesome job! I'm working through the same process atm...taking down the motor completely for restoration. This is of great help!! Thx for taking the time!!

New rider/mechanic of '85 VN700 Vulcan. (25k miles)

Link to bike restoration blog:
http://trailofthewolf.blogspot.com/s...%20Restoration
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post #10 of 109 (permalink) Old 05-14-2011, 04:45 AM
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Nice tear down. I have a comment tho, when you take the cams out would it be better to take out the ACCT's first? That way it takes tension off of the cams when you pull the plates off. I noticed that the cams were at an angle from the heads when you took off the cam plates from the tension on the chains. I believe it would also make it a little easier to get the cam plates off of the cams without the tension on the chain.
also are you going to replace the HLA's? If not does it matter which hole they go back in? I know on a multiple cylinder setup, I always put the valve train parts in order so that I can put them all back in the same order so they will wear the same. Especially a cam and lifters in a V-8 engine.
Again awesome job, I'm not telling you what to do of course, just a few comments.
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