My wad of mods - Kawasaki Vulcan Forum : Vulcan Forums
 
LinkBack Thread Tools Display Modes
post #1 of 6 (permalink) Old 07-13-2016, 10:51 PM Thread Starter
Lifetime Premium
 
Sabre-t's Avatar
 
Join Date: May 2015
Location: Marietta, GA
Year/Make/Model: 2010 Kawasaki Voyager
Displacement/CC's: 1700
Color: Red/Black
Gender: Male
Posts: 1,087
Garage
My wad of mods

I haven't been able to ride for a couple of months (medical issues) but I have been able to work on the bike some days. So I have done several mods and finally got a chance to test them out today.

I'll write them up and post pics as quickly as I can, but here's the list:

Fuse block
Cut down a tall shield to make a shorty
Installed fairing bags
Installed 2 Wolo horns
Mounted the EJK where I can see it better
Adjusted the belt tension
Fixed a crack in the fairing
Stopped a vibration in the tank top tupperware
Beefed up the ignition wiring (the recall issue)

The easiest one is to write up is the belt tension so I'll start with it. When I changed my back tire, I set the belt tension (with a borrowed tool) to the least amount recommended by Kawi at 5 mm. Well, I got the dreaded tranny whine at that tension. I got this tool off Ebay (a lot cheaper than the Amazon price in the link below):

https://www.amazon.com/Motorcycle-Te.../dp/B009YEYLKS

But had to cut one of the uprights off for it to fit inside the belt guard. Anyway, I set the tension to 10 mm this time and no more tranny whine. Tracking is dead center on the pulley.

More to come...

Installed:
RAM mount for TomTom Rider 400 (with anti theft module)
6000k LED Headlight & Spots; Kisan Headlight Modulator (works with LEDs),
__Brake Light Modulator, LED License Plate Holder
Longer Kickstand
Dobeck EJK 3.0
Lucky Mirror Extenders
Misc. RAM Mounts for Cup Holder, SPOT, Phone, etc.
Chuckster BAK, Trailer Hitch and Cooler Rack
Wiring for Trailer
Ray's Throttle Mod
Things to do:
Drilling Baffle Plates (Maybe)
Paint HF Tag Along Trailer to Match Bike

LET'S RIDE
Sabre-t is offline  
Sponsored Links
Advertisement
 
post #2 of 6 (permalink) Old 07-13-2016, 11:01 PM Thread Starter
Lifetime Premium
 
Sabre-t's Avatar
 
Join Date: May 2015
Location: Marietta, GA
Year/Make/Model: 2010 Kawasaki Voyager
Displacement/CC's: 1700
Color: Red/Black
Gender: Male
Posts: 1,087
Garage
Part 2: I forgot to take pics of my repair of the crack in the fairing. Facing the front of the bike, I had a crack behind the left side of the headlight trim that extended upwards from the bottom. I got some epoxy JB Weld for Plastic. They have 2 kinds that I know of, one is quick setting and one is slower setting. The slow setting is much stronger and more heat resistant, so I used that. I only put it on the inside because I didn't want to have to paint it and it is hidden. I put a wide (1 1/2") swath over the crack and also pretty thick. I let it cure for 24 hours to get maximum strength before remounting it. It seems to be holding very well. I will update if that changes.

Installed:
RAM mount for TomTom Rider 400 (with anti theft module)
6000k LED Headlight & Spots; Kisan Headlight Modulator (works with LEDs),
__Brake Light Modulator, LED License Plate Holder
Longer Kickstand
Dobeck EJK 3.0
Lucky Mirror Extenders
Misc. RAM Mounts for Cup Holder, SPOT, Phone, etc.
Chuckster BAK, Trailer Hitch and Cooler Rack
Wiring for Trailer
Ray's Throttle Mod
Things to do:
Drilling Baffle Plates (Maybe)
Paint HF Tag Along Trailer to Match Bike

LET'S RIDE
Sabre-t is offline  
post #3 of 6 (permalink) Old 07-13-2016, 11:36 PM Thread Starter
Lifetime Premium
 
Sabre-t's Avatar
 
Join Date: May 2015
Location: Marietta, GA
Year/Make/Model: 2010 Kawasaki Voyager
Displacement/CC's: 1700
Color: Red/Black
Gender: Male
Posts: 1,087
Garage
Part 3: Again, I forgot pics, but this one is easy to describe. Actually, two different things. First, I have checked the ignition wires for rubbing per the recall and have not had any wearing on the wires at all. But to be safe and not have to take it in, put some corrugated split loom tubing:

https://www.amazon.com/Electric-Prot...ire+protectors

around the wires and zip tied them so they would be secure. Now if any rubbing should occur it will be on that first.

While I had the "chrome" piece off the top of the tank, I used some 3M hook and loop (could have used double sided tape, but I had this handy) and some thin rubber material I had and made the pads that keep the front of the chrome off the tank thicker and also added some padding to the notch at the very front that sits right on the ignition assembly. I think that may be where most folks are getting vibration. The plastic is actually riding on the metal there with no padding at all. Anyway, I had absolutely NO vibration coming from the tank area for the first time today.

BTW, the best 3M exterior hook and loop (Velcro) is GREAT! The glue backing sticks in temperatures that no other hook and loop product I have tried does. You can still peel it off most surfaces if you need to (I wouldn't try that on a visible painted surface, though), but it won't melt off in the worst summer heat. Not even in the Mojave.

Installed:
RAM mount for TomTom Rider 400 (with anti theft module)
6000k LED Headlight & Spots; Kisan Headlight Modulator (works with LEDs),
__Brake Light Modulator, LED License Plate Holder
Longer Kickstand
Dobeck EJK 3.0
Lucky Mirror Extenders
Misc. RAM Mounts for Cup Holder, SPOT, Phone, etc.
Chuckster BAK, Trailer Hitch and Cooler Rack
Wiring for Trailer
Ray's Throttle Mod
Things to do:
Drilling Baffle Plates (Maybe)
Paint HF Tag Along Trailer to Match Bike

LET'S RIDE
Sabre-t is offline  
 
post #4 of 6 (permalink) Old 07-14-2016, 06:19 PM Thread Starter
Lifetime Premium
 
Sabre-t's Avatar
 
Join Date: May 2015
Location: Marietta, GA
Year/Make/Model: 2010 Kawasaki Voyager
Displacement/CC's: 1700
Color: Red/Black
Gender: Male
Posts: 1,087
Garage
Part 4: I wanted to power some devices without having everything connected directly to the battery, so I installed a fuse block:

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

It has a 100 amp max limit. I wanted some devices to have power even if the ignition is off, so it is not dependent on switched power. So far I have my trailer light controller, which is independently powered from the rear lights, and 2 Wolo horns attached. All three devices need 20 amp fuses, but will never pull the full 20 amps each (at most, the total will be about 45 amps).

I mounted it using a bracket from an old speedo, which worked perfectly. I have a cheap label maker that I used to mark what is attached to each position.

Everything is run off relays. The trailer lights from the rear running lights and the horns off the OEM horn. I am planning to add a switch box for powering devices such as my GPS and Phone even when the ignition is in the off position.
Attached Thumbnails
Click image for larger version

Name:	Fuse Block 2.jpg
Views:	68
Size:	94.3 KB
ID:	169570   Click image for larger version

Name:	Fuse Block 3.jpg
Views:	79
Size:	84.8 KB
ID:	169578  

Installed:
RAM mount for TomTom Rider 400 (with anti theft module)
6000k LED Headlight & Spots; Kisan Headlight Modulator (works with LEDs),
__Brake Light Modulator, LED License Plate Holder
Longer Kickstand
Dobeck EJK 3.0
Lucky Mirror Extenders
Misc. RAM Mounts for Cup Holder, SPOT, Phone, etc.
Chuckster BAK, Trailer Hitch and Cooler Rack
Wiring for Trailer
Ray's Throttle Mod
Things to do:
Drilling Baffle Plates (Maybe)
Paint HF Tag Along Trailer to Match Bike

LET'S RIDE
Sabre-t is offline  
post #5 of 6 (permalink) Old 07-14-2016, 11:22 PM Thread Starter
Lifetime Premium
 
Sabre-t's Avatar
 
Join Date: May 2015
Location: Marietta, GA
Year/Make/Model: 2010 Kawasaki Voyager
Displacement/CC's: 1700
Color: Red/Black
Gender: Male
Posts: 1,087
Garage
Part 5a: Shorty windshield and fairing bags.

When I purchased the bike it had the Kawi tall 16" shield on it. I'm pretty tall (6' 3") and could not see over it. No good. So I got a the Kawi mid-sized shield (14").

The 14" shield is good for cold weather, but I don't get enough air in the summer, so I decided to cut the tall shield down and make a shorty shield out of it. I wanted it just tall enough to be an inch or so higher than a set of fairing bags I also wanted to install.

I had the tall shield taped with masking tape and ready to mark. I was going to use the curve of the 14" shield as the pattern for the cut shield, but it just didn't quite work with the bags. In disgust, I just happen to lay the 14" shield on the other one, but in the opposite direction and behold, the bottom of the 14" shield made a perfect pattern for cutting the taller shield! So that is what I used to mark it as seen in the pic 1 below. I used a saber saw with a coarse tooth wood/plastic blade to cut it. I'm not the best at following lines when cutting, so it's not perfect, but I am working on smoothing it out.

Next, the fairing bags would not mount as they were. The back piece is too short to go into the fairing and down to the bolts that hold it on. I have a couple of rolls of small Velcro straps that stick well to the backing of the bags and got the idea of using them to connect the bolts to the bags. As you can see from the pic 2, they have a cinch hole on one end. This is perfect for putting the bolt thru between the windshield mounting strip and the windshield itself. Then I measured where a second hole needed to be for the bolt to go thru the strips on the other side of the shield and made a hole there (pic 3). Pics 4 & 5 show how I did this.

I have reach the picture limit for a post, so on to the next post...
Attached Thumbnails
Click image for larger version

Name:	Shield 1.jpg
Views:	57
Size:	67.8 KB
ID:	169586   Click image for larger version

Name:	Shield 2.jpg
Views:	53
Size:	96.3 KB
ID:	169594   Click image for larger version

Name:	Shield 3.jpg
Views:	59
Size:	92.8 KB
ID:	169602   Click image for larger version

Name:	Shield 4.jpg
Views:	45
Size:	95.2 KB
ID:	169610   Click image for larger version

Name:	Shield 5.jpg
Views:	49
Size:	74.1 KB
ID:	169618  


Installed:
RAM mount for TomTom Rider 400 (with anti theft module)
6000k LED Headlight & Spots; Kisan Headlight Modulator (works with LEDs),
__Brake Light Modulator, LED License Plate Holder
Longer Kickstand
Dobeck EJK 3.0
Lucky Mirror Extenders
Misc. RAM Mounts for Cup Holder, SPOT, Phone, etc.
Chuckster BAK, Trailer Hitch and Cooler Rack
Wiring for Trailer
Ray's Throttle Mod
Things to do:
Drilling Baffle Plates (Maybe)
Paint HF Tag Along Trailer to Match Bike

LET'S RIDE
Sabre-t is offline  
post #6 of 6 (permalink) Old 07-14-2016, 11:30 PM Thread Starter
Lifetime Premium
 
Sabre-t's Avatar
 
Join Date: May 2015
Location: Marietta, GA
Year/Make/Model: 2010 Kawasaki Voyager
Displacement/CC's: 1700
Color: Red/Black
Gender: Male
Posts: 1,087
Garage
Part 5b:

After mounting the windshield, I straightened the strips out, holding them in place with a thin sheet of rubber that I had. I had to have the rubber between the strips and the bags to keep them from sticking to the bag backing before I got it into position. Once in position, I then pulled the rubber up and out, allowing the strips to grab and stick to the backing of the fairing bags. They hold quite securely! I was surprised just how immobile the bags are. Pics 6 - 8 show the installed bags.

Unfortunately, it doesn't look so good from the front (pic 9). I will cut a piece of that rubber material to put between the shield and the strips to hide them, then it should look OK (I hope!). I also need to put a support under the bags to raise the bottoms up just a tad. Right now, they block the top of the gauges and the LCD display just a little bit.
Attached Thumbnails
Click image for larger version

Name:	Shield 6.jpg
Views:	53
Size:	58.9 KB
ID:	169626   Click image for larger version

Name:	Shield 7.jpg
Views:	62
Size:	69.3 KB
ID:	169634   Click image for larger version

Name:	Shield 8.jpg
Views:	59
Size:	94.2 KB
ID:	169642   Click image for larger version

Name:	Shield 9.jpg
Views:	48
Size:	95.2 KB
ID:	169650  

Installed:
RAM mount for TomTom Rider 400 (with anti theft module)
6000k LED Headlight & Spots; Kisan Headlight Modulator (works with LEDs),
__Brake Light Modulator, LED License Plate Holder
Longer Kickstand
Dobeck EJK 3.0
Lucky Mirror Extenders
Misc. RAM Mounts for Cup Holder, SPOT, Phone, etc.
Chuckster BAK, Trailer Hitch and Cooler Rack
Wiring for Trailer
Ray's Throttle Mod
Things to do:
Drilling Baffle Plates (Maybe)
Paint HF Tag Along Trailer to Match Bike

LET'S RIDE
Sabre-t is offline  
Sponsored Links
Advertisement
 
Reply

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



Similar Threads
Thread Thread Starter Forum Replies Last Post
My $.02 on my mods.....since someone asked. aaron5140 Vulcan 900 2 05-18-2010 06:55 PM
Vulcan 800 : the mods on my bike groomergirl Vulcan 800 11 04-11-2010 07:21 PM
Mods for my soon to be delivered SE timmyg123 Vulcan 900 9 03-14-2010 07:37 PM
A couple of mods to my 09. LonnyB Vulcan 500 3 08-01-2009 05:35 AM
My Bike is Home, and a Couple Mods VN1600Dan Vulcan 1600 2 06-24-2009 11:09 AM

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