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Join Date: Nov 2007
Location: Chandler, Arizona
What year did this start happening? I have an '02 with 70,000+ miles which has never leaked. With only 8000 miles, it is most likely a defective gasket. Kawasaki never took the Vulcan 750 seriously, and sold it completely unchanged for 22 years with nothing but different colors. The used the tooling till it wore out, then discontinued the model. It is likely new parts will be made with that same worn out tooling, that would explain why my original cam chain tensioners lasted 15,000 miles, but the new oem ones I replaced them with only lasted 10,000 miles. I was not aware you could get aftermarket gaskets. I am about to pull the front bevel drive gearcase on mine, so I can get the driveshaft out for maintenance. I have never had the driveshaft out, thought I would do it right this time. It is a lot easier to remove that gearcase than the swingarm. Was going to use a stock gasket. I just replaced my clutch with a new Kawasaki gasket, and it seemed fine.
I think there is a design problem with the coolant passages between the cylinders and the bottom end, they come too close to the edge. There just isn't enough room for gaskets with enough material to properly seal these passages, and being so narrow, it would be easy to deform the gasket while installing it. As far as I know, this issue exists with all years of the Vulcan 750.
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