Join Date: Jan 2015
Location: A stone's throw from Luckenbach, TX
Year/Make/Model: 1996 Kawasaki Vulcan 800 Classic
Sounds like your bike runs crappy just like mine did when I got it. I recently semi-rebuilt a POS 1996 800 Classic. And I just got back from a Twisted Sisters/Kickapoo ride half way across Texas and back this past weekend. The bike performed flawlessly!
FIRST: How many miles are on it and are you getting spark to both plugs? If good sparks then you are correct, you need to go back to 100% stock on the carb. Ignore the V&H exhaust for now; I too have an aftermarket exhaust--Cobra.
Please put your city and your bike in your profile--the mod is going to ask you to anyway and it is helpful to folks wanting to help you.
TIP: Loosen only the carb side of your manifold boot to remove the carb and leave the engine side on. Use a long ball end allen, makes life easier loosing that allen bolt time and time again. Also, before you go all out, CHECK THE BOOT FOR AIR LEAKS. If your carb is on right now, get your bike to idle steady somehow then squirt starting fluid at the boot joints from the left side. If idle increases, you have a leak. (Some folks use carb cleaner.)
Pilot 48 (order a 50 also)
Jet needle N2PE
1 3/4 turns out (for now)
Make sure your fuel mixture screw isn't damaged and has its spring and its O-ring. Also . . .
How many miles?
Does it have the original fuel line? (Usually gray and flared on petcock side) Also, is there an aftermarket shut off valve on it?
When you turn your petcock to ON or RES does gas leak out? It should be a positive shut off in those positions. Is there a full flow if set to PRIME?
1996 Vulcan 800, Blue/Green
JUST SOLD: 2016 Indian Scout, Black
SOLD LAST YEAR: 2006 Triumph Rocket III, Black
SOLD LAST YEAR: 1967 Honda 305 Dream, Black
"Going up the country . . . "