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post #1 of 76 (permalink) Old 05-06-2020, 09:27 PM Thread Starter
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99 750 Vulcan

Hi new to the forum I have had my Vulcan for 2 years bought used for $2,000 us 10,000 miles I have had no issues with it except the past couple weeks battery has died and left me stranded I am new to working on bikes but I am great with Auto tech so I know there are 3 major components to the charging system battery which is new the stator and rectifier which I have just bought both new I am just going to replace everything I have figured out that it will charge when cold but as soon as the engine is hot it stops charging so I tested the stator and it definitely is bad looking to do the tuxedo mod any suggestions before starting
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post #2 of 76 (permalink) Old 05-07-2020, 05:43 AM
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Welcome to the machine!

Stator heats up, expands, metals ground out, dead stator. Good catch.

Be sure you're ready to do a clean accurate cut on the case . Oil leaks suck.

Check your balancer dampers.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
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Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
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post #3 of 76 (permalink) Old 05-07-2020, 06:36 AM Thread Starter
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Thanks what do you suggest for a cutting tool I watched a video where a drimal was used had alot of shavings was wondering if a small cut off tool would work better
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post #4 of 76 (permalink) Old 05-07-2020, 07:33 AM
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I've seen bad results and really good results. Depends on skill and patience of the craftsman.

I just pulled the cover and skipped the mod, got to the part of making a thicker gasket using silicone and froze up. Jason Pittenger has a thread going where it looks like he's handled the gasket gap problem in a good way. Been kinda impaired lately so I may not get everything right if I try to tell you.

Cutting the case away from the engine is the best plan, much easier to see you are getting an accurate cut. If I had to, I would use the machine shop at my old job, but they closed the doors for good last month. 75% of a global company, gone.

Aluminum cuts super quick and easy, going slow is key. You can remove, but can't put it back. Maybe draw a line, then sneak up on the line. Could make final trim even with coarse sandpaper if you absolutely had to. Need a CNC, anybody got one they can loan?

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
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Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
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post #5 of 76 (permalink) Old 05-07-2020, 07:36 AM
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heh .. two JPs. Jason and Jonathon, now I'll be cornfused again. We got two new M handles that I keep mixing up. I cannot be trusted!

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
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post #6 of 76 (permalink) Old 05-07-2020, 07:48 AM Thread Starter
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Yeah I was definitely going to draw a line and probably do a light pass to make a groove then on the second path cut all the way through
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post #7 of 76 (permalink) Old 05-07-2020, 08:47 AM
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https://www.vn750.com/forum/19-elect...-hole-saw.html

Check this out for one idea,
I’m not confirming or denying it’s merit because I have no personal experience.

Maybe someone who used this method will reply?

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Last edited by Scooter 007; 05-07-2020 at 08:49 AM.
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post #8 of 76 (permalink) Old 05-07-2020, 08:59 AM
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https://www.vn750.com/forum/19-elect...-mod-tips.html

Im thinking this is the thread Spockster is referring to. If not still worth a look .

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post #9 of 76 (permalink) Old 05-07-2020, 10:03 AM
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Quote:
Originally Posted by Scooter 007 View Post
https://www.vn750.com/forum/19-elect...-hole-saw.html

Check this out for one idea,
Im not confirming or denying its merit because I have no personal experience.

Maybe someone who used this method will reply?
Haven't done it, but having some guide is good. Should've asked that poster if he was in the industry. It's a method used to get portable mills chucked up onsite. Say, the forward weapons hatch on a submarine.

I'd probably have the case off and at the drill press.

2003-21k mi
Shaved w/UniPK92+Stock Jets-TPE/MOSFET-Shinko Tires-AGM batt-bags-chrome-LEDs...more
__________________________________________________ ____________
Repair Manual: http://www.mediafire.com/file/mj7z81..._Catalogue.pdf

Owner's Manual: http://www.mediafire.com/file/nscb5f...ers+Manual.pdf
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post #10 of 76 (permalink) Old 05-07-2020, 10:18 AM Thread Starter
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I think I am just going to do it I am nervous but I have been around tools since I was a kid and what is the worse that can happen I have to take the cover off and put a new one on
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