Engine Teardown Tips and Lessons - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 4 (permalink) Old 05-13-2007, 12:36 AM Thread Starter
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Engine Teardown Tips and Lessons

OK, here are a couple of items I have learned the hard way while replacing the lower cylinder gasket.

1) Have someone help while pulling the engine from the frame.

2) A set of mechanics picks (about $7 from Sears) are worth their weight in gold. They are very helpful in retreaving o-rings, getting clutch plates out of the basket, getting hoses to seat on pipes (such as the carb hoses to the intake manifold).

3) Go to Walmart and get 2 or 3 large muffin tins, a roll of masking tape, and a Sharpie. Label each cup with what is in it. You will not lose anything and putting the engine back together will be much easier.

4) The coolant pipe from the crankcase cover housing (right side) to the head is unidirectional. The end with the straight pipe (Orings will slip right off) goes into the head - other end with the swagged end goes into the crankcase housing.

5) To remove the spark plug housings (must be done to remove the cam chains), the Clymers calls for using a fat 27mm nut. Use the rear wheel nut. You will need to replace the cotter pin, but so what.

6) Purchase or borrow (preferably borrow since this is expensive) a good, high torque pneumatic wrench - it is essential for removing the clutch.

There will be more as I complete the process.


Last edited by [email protected]; 05-13-2007 at 08:06 AM.
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post #2 of 4 (permalink) Old 05-13-2007, 09:24 AM
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Good write up! This might be a good candidate to add to the verses.
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post #3 of 4 (permalink) Old 05-13-2007, 10:40 AM
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Jeff -

Some good info there, thank you.

What led you to the lower cylinder gasket? Was it externally leaking coolant, oil?

Haven't read the procedure yet, but clutch comes out no matter what when changing cylinder gaskets?


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post #4 of 4 (permalink) Old 05-13-2007, 07:38 PM Thread Starter
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It was externally leaking coolant. There were some other issues such as one of the back plugs constantly fouling (the other plug in the same cylinder didn't foul - wierd).

As soon as Bike Bandit gets the new gaskets to me, I will button it up and see if it runs. I took the opportunity to lube the cables while being held up on the other work.

It seems to be the project that never ends.

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