OVERHAUL - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 69 (permalink) Old 04-13-2016, 09:36 PM Thread Starter
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OVERHAUL

This thread might be something done before... but...

As of this morning, it took about 2 or 3 months to finally determine the "reality" shape of this bike. It has been determined that the engine must come out for a rebuild. And so a stator mod will be done "properly" instead of cutting out the plate while the bike is on the stand.

On the way "there". Need to pull the rear tire anyway, so, will be doing the splines inspection... and the electrical harness is 30 years old and the entire bike is going to be rewired anyways because i want a custom dash that has 3 toggle switches, and a couple of meters on it... so... at that point... may as well sand off the frame and paint her too.. remove the emissions, etc... etc... etc...

SOOOooooo the question here for "Overhaul" is...

What is the suggested order of operations for tearing a full bike down to its core... and rebuilding it?

This is more than just asking the order that "needs" to occur, but based on supply of parts... while waiting on "xyz" bearing to arrive... need to be working on something else anyways, etc... This is a question that can only be answered by "opinions", certainly, but i am hoping to hear how various people arrived at those opinions, and why.

Thanks in advance.
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post #2 of 69 (permalink) Old 04-14-2016, 02:08 AM
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You can tear the bike down in 2 hours or less. Literally every bolt. So that's pretty quick. Get the bike a part, then get to your engine.

You wont know what you need (aside from standard gaskets) until you break open the case and inspect it.

Order from a local dealer to get parts 3-5 days faster than online. Have them come close to online prices - they will if you are ordering a bunch (i.e. full rebuild stuff).

There is no rebuild 'kit', so you need to spec each gasket part # etc.

While you have parts down time on the engine sort out just about everything else.
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1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers
VN750.com Grill Cover
Meanstreak Seat
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1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

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post #3 of 69 (permalink) Old 04-14-2016, 02:47 AM Thread Starter
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Originally Posted by thtanner View Post
You can tear the bike down in 2 hours or less.
LOL. Maybe you can. But ima old and slow and careful and have a flight of stairs i need to carry that engine up among all the rest . . .

good exercise and i realize you meant "you" in general for others.

but seriously laughed when i read that. LOL

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post #4 of 69 (permalink) Old 04-14-2016, 03:16 AM
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Careful with the engine, threw out my back dead lifting it last time.

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
TOC MCCTs
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers
VN750.com Grill Cover
Meanstreak Seat
Emgo 23-92411 Handlebars
MOSFET FH012AA R/R


1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

2014 Honda VFR800F

1989 Pontiac Firebird Formula 350
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post #5 of 69 (permalink) Old 04-14-2016, 03:39 AM Thread Starter
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Originally Posted by thtanner View Post
Careful with the engine, threw out my back dead lifting it last time.
My plan is to do an engine "migration" up the stairs. So.. lining up getting a jack from a friend to loan... put some wood on top of it, whatever.. use the jack to support engine close to the bike, by that time the tank will be off, etc.. So with enough top end access, remove the carbs, then the heads, and basically one chunk at a time, strip a handful of parts off the engine until it's as light as can be.

It weighs in at ~150 IIRC. so... can probably knock off 50 pounds if lucky. Lifting 100 pounds is not a big deal even with a slipped disc history for me... but omg... those stairs? I lost some ligaments in that wreck back in my twenties. And this is going to be UP and DOWN and UP and DOWN those stairs over and over for uhm...

yeah right... two hours. . hahahahahahahahaha OMG.... too funny.
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post #6 of 69 (permalink) Old 04-14-2016, 09:26 AM
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Quote:
Originally Posted by RoadHopper View Post
LOL. Maybe you can. But ima old and slow and careful and have a flight of stairs i need to carry that engine up among all the rest . . .

good exercise and i realize you meant "you" in general for others.

but seriously laughed when i read that. LOL

Stripped mine in four with beer,coffee and lunch breaks
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post #7 of 69 (permalink) Old 04-14-2016, 09:38 AM
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Step one, take some high-res pics all around the bike.

What about assembly? Are you carrying it back downstairs in one piece?

Might be better to strap it to a dolly, then you just have to heave one step at a time.
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post #8 of 69 (permalink) Old 04-14-2016, 10:04 AM
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Originally Posted by Spockster View Post
Step one, take some high-res pics all around the bike.

What about assembly? Are you carrying it back downstairs in one piece?

Might be better to strap it to a dolly, then you just have to heave one step at a time.
Oh, yeah. I also recommend taking pictures before and crap ton during the removal. Especially as you remove parts and bolts, so that you can refer back to them later and install the right pieces in the right location.

Don't trust your yourself to remember all these little details unless you have a photographic memory, in which case I'm jealous.
Also devise a system in which you can neatly organize all the bolts and not just mix them all in a bowl.
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post #9 of 69 (permalink) Old 04-14-2016, 10:38 AM
..have a vulcan good day!
 
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Quote:
Originally Posted by evulcannibal View Post
Oh, yeah. I also recommend taking pictures before and crap ton during the removal. Especially as you remove parts and bolts, so that you can refer back to them later and install the right pieces in the right location.

Don't trust your yourself to remember all these little details unless you have a photographic memory, in which case I'm jealous.
Also devise a system in which you can neatly organize all the bolts and not just mix them all in a bowl.

ditto on all the above
.......suggest purchased box's of various size zip lock bags - bagging associated nuts/bolts/parts together in groups....
clean as you reassemble

and rags...go to Goodwill on 50% off day....huge assortment of suitable rags for cheap ! (in 2xxl & 3xxxl sizes - - )

You also will need an 18mm x _?__ bolt to pull the flywheel....

'86 VN750 13,700 mi -Stock
-Purchased 2008 w/8800mi
Replaced ALL Cables . Kuryakyn LED Voltmeter
SilverStar Ultra 9003/HB2 H4 Headlamp, Jardine Fwd Controls,
Iridiums DPR7EIX-9 & Wires, Tuxedo Mod, Coil Mod, P/U Sensor Mod, Fork Seals,
Splines Lubed - 11/4/2012 - MF AGM Battery
Additional Flashing LED Brake Light on Trunk
Dampers went out @ 13+K !
After TOC MCCT's..... so amazingly quiet I discovered a rattling heat shield on my stock exhaust !
...have a vulcan good day!

Last edited by WilliamTech; 04-14-2016 at 10:52 AM.
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post #10 of 69 (permalink) Old 04-14-2016, 10:58 AM
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Quote:
Originally Posted by WilliamTech View Post


ditto on all the above
.......suggest purchased box's of various size zip lock bags - bagging associated nuts/bolts/parts together in groups....
clean as you reassemble

You also will need an 18mm x _?__ bolt to pull the flywheel....
18x1.5mm, also available as Motion Pro 08-0116 for about $9 online.

Ditto to the zip lock bags. Grab a box of the cheap ones from the store and a wide tip permanent marker. The fine point ones try to push into the plastic on the bag too easily.
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