Bought a basket case winter project - Kawasaki Vulcan Forum : Vulcan Forums
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 20 (permalink) Old 12-03-2012, 04:28 PM Thread Starter
Top Contributor
 
Bandit101's Avatar
 
Join Date: Sep 2009
Location: Western NC
Posts: 645
Bought a basket case winter project

Got the new jets installed and tuned the carb. Took bike for first test ride and everything seems OK. Amazing how quickly this project came together. Guess I will have to find another winter project now.


Current progress Up date. Well the engine is installed and today I started it up. Amazing how smooth it runs. I'm impressed. Came with the V&H Longshots and they really sound good. Have not done the road test yet, still finishing up odds & ends but progressing much better than expected. Look below for pictures with engine installed.





Early last week while scanning the adds on Craigs List, I came across an add for a 2004 Kawasaki 1500 Vulcan Classic. 30K, engine had spun a bearing, been sitting for 2yrs, $1000, OBO. So I call the guy up, find out he is only 75miles from me, he describes the bike as excellent shape, never down, been stored in his garage since engine went out. Seems he was on a trip to Va from NC when bike lost oil to rod bearings and burnt the bearings and ruined the crankshaft. Had it towed to a dealership where they tore the engine down and told him it would need a complete rebuild. Said he was never able to come up with the extra money to have the repairs done and finally decided to sell it. Told him if it was what he described I would pay the full $1000, and be there Friday morning. So with cash in hand and trailer in tow my trusty GPS took me straight to his driveway Friday morning. It was as he described and I brought it home.
Now some of you may know I previously had a 1999, 1500 classic that the POG failed in and I replaced it with a JOG. Worked fine except for a constant engine whining. Being skeptical and proactive I purchased a 2002, used engine, tore it down, rebuilt and kept it for a spare. Last summer I bought a HD Ultra Classic and since I wasn't riding the Kaw anymore my son took it over.
I still have the spare engine I rebuilt and now have a bike it should fit right into. The one question I do have, is the original engine from the bike has a single stator charging system and my replacement engine has a dual stator.
Does anyone know if these are paralleled in the connector, or do they have seperate connection plugs?
Here are some pictures of the project.








Last edited by Bandit101; 01-01-2013 at 10:58 AM. Reason: update
Bandit101 is offline  
Sponsored Links
Advertisement
 
post #2 of 20 (permalink) Old 12-03-2012, 07:22 PM
Top Contributor
 
Join Date: Apr 2009
Posts: 8,467
The two systems run in parallel....a poor set-up that incredibly gives little trouble.
sfair is offline  
post #3 of 20 (permalink) Old 12-03-2012, 07:26 PM Thread Starter
Top Contributor
 
Bandit101's Avatar
 
Join Date: Sep 2009
Location: Western NC
Posts: 645
Quote:
Originally Posted by sfair View Post
The two systems run in parallel....a poor set-up that incredibly gives little trouble.
Thank you. Should be an easy installation then.
Bandit101 is offline  
post #4 of 20 (permalink) Old 12-03-2012, 07:33 PM Thread Starter
Top Contributor
 
Bandit101's Avatar
 
Join Date: Sep 2009
Location: Western NC
Posts: 645
I also noticed the pistons are stamped .05m. Is this an oversize? Seems strange for a
low milage motor.
Bandit101 is offline  
post #5 of 20 (permalink) Old 12-04-2012, 06:57 PM
Senior Member
 
screwedandtattooed's Avatar
 
Join Date: Aug 2012
Location: Little Rock, Arkansas
Posts: 117
That'll be a nice project and it'll be awesome when its done. I'd like to get my hands on a project bike but alas I don't have the time or money.


Sent from my iPhone using Motorcycle.com Free App

'97 vulcan 1500 classic carb
vance and hines straight shots
screwedandtattooed is offline  
post #6 of 20 (permalink) Old 12-05-2012, 10:46 AM
Top Contributor
 
Join Date: Apr 2009
Posts: 8,467
Quote:
Originally Posted by Bandit101 View Post
I also noticed the pistons are stamped .05m. Is this an oversize? Seems strange for a
low milage motor.
It would not be out of the realm of possibilities ( besides all other possibilities)that the piston was factory installed to correct for machining errors, or the piston is mis-marked. Measurement would tell the story.
sfair is offline  
post #7 of 20 (permalink) Old 12-05-2012, 03:38 PM Thread Starter
Top Contributor
 
Bandit101's Avatar
 
Join Date: Sep 2009
Location: Western NC
Posts: 645
Today I measured the pistons and they are 4.020. They are manufactured by ART.
Seems someone had previously been into this engine. I am surprized the crankcase
main bearings are perfect, considering the condition of the rod bearings.
Bandit101 is offline  
post #8 of 20 (permalink) Old 12-05-2012, 03:48 PM
Top Contributor
 
Join Date: Apr 2009
Posts: 8,467
I cannot see the crank being salvageable with those rod bearings.
The case mains "measure" OK?
sfair is offline  
post #9 of 20 (permalink) Old 12-05-2012, 04:11 PM Thread Starter
Top Contributor
 
Bandit101's Avatar
 
Join Date: Sep 2009
Location: Western NC
Posts: 645
You are correct, the rod journals were beyond any repair. For some reason the owner wanted to keep it as a momento. Yes, the case mains measure good.
Bandit101 is offline  
post #10 of 20 (permalink) Old 12-11-2012, 06:34 PM Thread Starter
Top Contributor
 
Bandit101's Avatar
 
Join Date: Sep 2009
Location: Western NC
Posts: 645
Check the updated pictures. Engine installed.
Bandit101 is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki Vulcan Forum : Vulcan Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome