Pulling Engine to replace head gasket - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
 
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post #1 of 7 (permalink) Old 12-04-2019, 07:21 PM Thread Starter
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Pulling Engine to replace head gasket

I don't know if I have anything useful to add, but I thought I would post pictures of my progress for anyone interested.

I haven't removed the front bevel assembly yet.
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'89 VN750 Bought stock 4/12/18 @ 17805.9 miles $800. Wrecked once. 27454.5+ miles

Completed modifications:
Removed mufflers, straight pipes out of GB. 110/90 Front Tire. Pick-up coil mod. Shindengen MOSFET FH020AA r/r. USB Outlet + Voltmeter. Repainted Metallic Blue w/ new tank bages. Ear Shave (wo/ coasters) 40/140 NO shims 45MPG. MCCT conversion.

Planned modifications:
Custom LED turn signals. Windshield. Highway Pegs. (Possible) ignition adv. Tuxedo Mod. Ignition coil mod.
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post #2 of 7 (permalink) Old 12-04-2019, 09:36 PM
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I left the bevel gear on mine, but I only tilted the engine. You have to be able to manage stabbing the driveshaft onto the gear as the engine goes in, has to happen before any bolts can go in. Impossible for one person hefting the engine by hand or even on a jack most likely.

Left the exhaust manifolds on too.

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 #3 of 7 (permalink) Old 12-05-2019, 10:31 AM
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bevel gear is relatively easy to remove, and reinstall. only tough part is stabbing the front of the driveshaft into place as you install the gear assembly (would be same if you didnt remove the bevel gear, but with the rest of the engine 'helpin' you screw it up or get mad at it).

the only thing to remember about removing the bevel gear from the driveshaft is to keep the driveshaft as far rearward as possible to prevent it from dropping off the rear splines, or you have your work cut out trying to align them

2005 VN750

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post #4 of 7 (permalink) Old 12-05-2019, 11:10 AM
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I should add, while I left the bevel gear in place, the rear gear was removed which made it easier to manipulate the shaft (was doing rear tire and spline lube at the same time).

At the time my thinking was, one less gasket, and to remove the least amount of parts as possible. The carbs, cables, exhaust manifolds, etc. Also had an extra pair of hands when the engine went back in place. Did it twice in two days!

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 #5 of 7 (permalink) Old 12-06-2019, 03:21 PM Thread Starter
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My drive shaft came off the rear spline while pulling the bevel case. But I've taken the rear apart before and it wasn't terrible. Just one more thing to assemble later on. For now, it's just sitting in the shaft casing.

It looked like the bevel case had its own fill and drain port on it. But I don't recall noticing these before.
It also didn't have its own fluid in it, just engine oil.

I plan to tinker on the engine over a period of a couple months. I'm in no rush. I have until April. My wife wasn't happy with the parts all over the garage, so they're neatly tucked onto shelves now.

With few exceptions, I've been able to put every screw back into it's spot after removing the item. This helps me keep track of the screws. Only the subframe bolts and the bevel gear cover screws have had to remain off.

The front spline looked good (unworn) but dry. Should that have moly grease on it?
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'89 VN750 Bought stock 4/12/18 @ 17805.9 miles $800. Wrecked once. 27454.5+ miles

Completed modifications:
Removed mufflers, straight pipes out of GB. 110/90 Front Tire. Pick-up coil mod. Shindengen MOSFET FH020AA r/r. USB Outlet + Voltmeter. Repainted Metallic Blue w/ new tank bages. Ear Shave (wo/ coasters) 40/140 NO shims 45MPG. MCCT conversion.

Planned modifications:
Custom LED turn signals. Windshield. Highway Pegs. (Possible) ignition adv. Tuxedo Mod. Ignition coil mod.

Last edited by Jason Pittenger; 12-06-2019 at 03:45 PM.
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post #6 of 7 (permalink) Old 12-06-2019, 06:28 PM
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on the bevel case, it gets lubrication from the engine/transmission. no separate supply. probably just had some leftover sitting in it. so, engine oil is the proper lube for the case

front splines dont tend to wear out, but a little moly on them wont hurt a thing

2005 VN750

Sold 11-27-17
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post #7 of 7 (permalink) Old 12-07-2019, 11:34 AM Thread Starter
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And so it begins...
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'89 VN750 Bought stock 4/12/18 @ 17805.9 miles $800. Wrecked once. 27454.5+ miles

Completed modifications:
Removed mufflers, straight pipes out of GB. 110/90 Front Tire. Pick-up coil mod. Shindengen MOSFET FH020AA r/r. USB Outlet + Voltmeter. Repainted Metallic Blue w/ new tank bages. Ear Shave (wo/ coasters) 40/140 NO shims 45MPG. MCCT conversion.

Planned modifications:
Custom LED turn signals. Windshield. Highway Pegs. (Possible) ignition adv. Tuxedo Mod. Ignition coil mod.

Last edited by Jason Pittenger; 12-07-2019 at 06:29 PM.
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