Gasket Install Instructions? - Kawasaki Vulcan Forum : Vulcan Forums
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 20 (permalink) Old 06-27-2013, 09:17 AM Thread Starter
Member
 
tmartin62's Avatar
 
Join Date: May 2013
Location: Mississippi
Posts: 35
Gasket Install Instructions?

Ok, I called myself looking but I did not find a thread that explained how to install the throttle body gasket.

My bike has less than 800 miles but I have some popping. It's not too bad but I want to get rid of it.

I'm not really sure where to start on the install? I'm assuming everything is under the left side breather cover... Are there any gotcha's? What all has to be removed to get to the gasket.

Thanks in advance for any help...

When I do mine, I will take pictures and document the process for anyone else that needs to do it in the future.

Tommy
tmartin62 is offline  
Sponsored Links
Advertisement
 
post #2 of 20 (permalink) Old 06-27-2013, 09:48 AM
Lifetime Premium
 
RACNRAY's Avatar
 
Join Date: May 2011
Location: SOUTH FLORIDA
Posts: 1,667
The quickest and easiest method to affect a decrease or outright elimination of popping on decel is to cancel out the kleen air system.
This system allows air to enter the exhaust ports to minimize emmissions, but is well known for being a major contributor to popping on decel.
The hose that feeds this system connects to the RIGHT SIDE airbox base, to the back side of the base at about the 11 oclock spot. Removing the hose and inserting a marble into the hose is one way, but plugging the hole in the airbox with hi-temp silicone is our method and very quick and easy.

As far as the t/b gasket, the work is performed on the RIGHT SIDE of the intake system. The complete right side air box must be removed and the throttle body removed from the intake manifold. The gasket goes in between and you must also use the stock o-rings in there original grooves. I also recommend using a thin film of hi-temp sealant on the gasket.

I would HIGHLY recommend getting a service manual. This really is not a job without some experience and/or being able to refer to a service manual.

RACNRAY

"TRUE HAPPINESS IS IN THE HEART,NOT IN THE OUTSIDE FIXES!!"
WITH OVER 42 YEARS AS A MOTORCYCLE TECHNICIAN/HI-PO SHOP OWNER I AM A PURVEYOR OF FACT NOT FICTION!
"WE LIVE OUR LIVES IN CHAINS NEVER KNOWING WE HAD THE KEY"
RACNRAY is offline  
post #3 of 20 (permalink) Old 06-27-2013, 10:02 AM Thread Starter
Member
 
tmartin62's Avatar
 
Join Date: May 2013
Location: Mississippi
Posts: 35
Thanks Ray. That is exactly what I needed.

I'm assuming the popping isn't really causing any harm. I called Kawasaki and they said it was normal.

I have had bikes since I was 16 and I'm 51 now. This is the first one I have had that pops this much.


Sent from Motorcycle.com Free App
tmartin62 is offline  
 
post #4 of 20 (permalink) Old 06-27-2013, 10:32 AM
Lifetime Premium
 
RACNRAY's Avatar
 
Join Date: May 2011
Location: SOUTH FLORIDA
Posts: 1,667
The popping does not cause any harm.

"TRUE HAPPINESS IS IN THE HEART,NOT IN THE OUTSIDE FIXES!!"
WITH OVER 42 YEARS AS A MOTORCYCLE TECHNICIAN/HI-PO SHOP OWNER I AM A PURVEYOR OF FACT NOT FICTION!
"WE LIVE OUR LIVES IN CHAINS NEVER KNOWING WE HAD THE KEY"
RACNRAY is offline  
post #5 of 20 (permalink) Old 06-27-2013, 08:39 PM
Senior Member
 
Join Date: Apr 2011
Location: Fitchburg, WI
Year/Make/Model: 2009 Kawasaki Classic
Displacement/CC's: 1700
Color: Black
Gender: Male
Posts: 186
Garage
Ray - Is that the hose Joe has you plug when installing his big air kit?

Stitch
Stitch is offline  
post #6 of 20 (permalink) Old 06-27-2013, 09:55 PM
Top Contributor
 
new kawi rider's Avatar
 
Join Date: Apr 2012
Location: shelbyville il
Posts: 636
Quote:
Originally Posted by Stitch View Post
Ray - Is that the hose Joe has you plug when installing his big air kit?
That is the hose ! Ray if that hose attaches to the back of the airbox and I plugged the hose does that mean I have a hole in the back of my air box now ? The hose is not attached to the back of my airbox now.


Sent from Motorcycle.com Free App

2010 Voyager
Scootworks 2 inch fat risers
vance&Hines slipons
Mustang Wide Touring studded
PCV
Michelin commander 2
Ipod adapter
Titanium header wrap
8 to 12.5 inch bagger windshield
Iso grips with Rays throttle mod
Chrome rear floor board covers
Kams Kit
new kawi rider is offline  
post #7 of 20 (permalink) Old 06-28-2013, 02:05 AM
Senior Member
 
jase64's Avatar
 
Join Date: Aug 2012
Location: Spencer Massachusetts
Posts: 440
Garage
i installed cobra tri ovals wich is making my bike do alot of popping , if i stick to 89 octane its not as bad , but its loud sometimes depending on the weather. will blocking the hose help? and do i need to block the hole thats left? i really dont want to get into air kits and comanders.. i spent enough already . your help is well appreciated if i lived down there you'd get all my business.
jase64 is offline  
post #8 of 20 (permalink) Old 06-28-2013, 08:25 AM
Lifetime Premium
 
RACNRAY's Avatar
 
Join Date: May 2011
Location: SOUTH FLORIDA
Posts: 1,667
Quote:
Originally Posted by new kawi rider View Post
That is the hose ! Ray if that hose attaches to the back of the airbox and I plugged the hose does that mean I have a hole in the back of my air box now ? The hose is not attached to the back of my airbox now.

YES...plug up the hole in the a/b with hi=temp silicone.

Sent from Motorcycle.com Free App
Quote:
Originally Posted by jase64 View Post
i installed cobra tri ovals wich is making my bike do alot of popping , if i stick to 89 octane its not as bad , but its loud sometimes depending on the weather. will blocking the hose help? and do i need to block the hole thats left? i really dont want to get into air kits and comanders.. i spent enough already . your help is well appreciated if i lived down there you'd get all my business.
Plug the hose and the hole, will help to reduce popping on decel.

RACNRAY

"TRUE HAPPINESS IS IN THE HEART,NOT IN THE OUTSIDE FIXES!!"
WITH OVER 42 YEARS AS A MOTORCYCLE TECHNICIAN/HI-PO SHOP OWNER I AM A PURVEYOR OF FACT NOT FICTION!
"WE LIVE OUR LIVES IN CHAINS NEVER KNOWING WE HAD THE KEY"
RACNRAY is offline  
post #9 of 20 (permalink) Old 06-29-2013, 01:26 AM
Senior Member
 
jase64's Avatar
 
Join Date: Aug 2012
Location: Spencer Massachusetts
Posts: 440
Garage
Quote:
Originally Posted by RACNRAY View Post
Plug the hose and the hole, will help to reduce popping on decel.

RACNRAY
thank you ray it seems to help . it popped a little , not like it was ,i can live with that. if it ever stops raining i'll be able to take a long ride and give a better report. would a air kit or k&n filter help more? if so wich one ?

Last edited by jase64; 06-29-2013 at 01:29 AM. Reason: bad spelling ..lol
jase64 is offline  
post #10 of 20 (permalink) Old 07-13-2013, 09:55 AM
Top Contributor
 
DrNo's Avatar
 
Join Date: Jun 2009
Location: Lethbridge, Alberta
Posts: 900
I kinda like the poping n burbling on decel.

09 - 1700 Nomad
DrNo 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
Is head gasket same as jug gasket? mcdowell92 Vulcan 500 2 04-11-2016 08:19 PM
900 Hypercharger install instructions link here xxxxxxRTL Rider Vulcan 900 0 02-16-2012 06:33 PM
Looking for Front Pulley Instructions crooksie Vulcan 900 1 01-30-2010 05:43 PM
Lowering kit instructions David121582 Vulcan 900 12 05-12-2009 10:35 AM
Instructions on how to install saddlebag mounting brackets 2kvulcan Vulcan 2000 2 05-07-2009 11:29 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