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General Information

Name
Kawasaki Vulcan 800
Year
2003
Model
Classic
Color
green
History
Used cars purchased this year
Kawasaki Vulcan 800 failed to start in 2003, the symptoms are as follows:
1. You can start in second gear when sliding downhill.
2. The starter motor has been replaced with a new one, and the starter gear has also been replaced.
3. Try to connect the starter motor directly with the battery, occasionally it can only make half a circle or one circle, and then stop, the current is huge.
4. Use a wrench to rotate the power system, except that it’s a bit hard when the piston runs to the top, it’s not difficult to rotate.
I can't figure out the problem at all, please help masters!

Comments

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  1. Make certain that the battery you are using is GOOD and FULLY charged.
  2. Make sure the unit is in Neutral.
  3. Remove spark plugs and ground them AWAY from spark plug holes.
  4. Rotate, BY HAND, the crank to see if the cylinders are hydro-locked from leaking fuel.
  5. IF and ONLY when the cylinders are clear of excess fuel, then try to start the unit with the starter system.
If the starter doesn't turn the motor at this point then you still have an issue with a component in the starter system (electrical and/or mechanical) or, less likely but possible, the crank shaft, rod and piston, and/or valve train have a problem.
Make sure the frame ground has good contact and the cable to the battery isn't corroded internally. If you can see copper 'rust' (bluish powdery substance) at the cable and going into the cable then that could be the issue. Same for positive battery cables.
Does the engine have oil or has it ever been run without oil or the proper amount of oil?
Is/are the cylinders hydro-locked from fuel leaking into the cylinders from dirty carbs?
Have you tried to start with a known GOOD, FULLY charged battery? Don't assume the one you are using is good enough for the task.
From your "symptoms" list you meant that you can bump start the unit. That indicates the ignition circuit is fine but says nothing of the starter circuit.
A new starter and gear. Does that mean the starter one-way clutch was replaced as well? The one-way clutch fail is more common than anything.
It is not LIKELY but is POSSIBLE that the 'new' starter is refurbished and could be a bad unit.
Finally, if there is excessive carbon build up on the piston crowns and in the combustion dome then the increased compression ratio could prevent the crankshaft from rotating.
 

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Thank you very much for your reply!
1. Use an external battery to directly connect to the terminal of the starting motor without passing through the starting circuit.
2. Remove the spark plug and start the motor to work normally.
3. The one-way clutch is normal.
4. The whole system can be rotated with a wrench. It is difficult to rotate at the apex of the piston, but it can be rotated.
5. There is no problem with the disassembly of the starting motor. I feel that the power of the starting motor should not be enough. I plan to buy another one to try.
 

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Registered
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0 Posts
Thank you very much for your reply!
1. Use an external battery to directly connect to the terminal of the starting motor without passing through the starting circuit.
2. Remove the spark plug and start the motor to work normally.
3. The one-way clutch is normal.
4. The whole system can be rotated with a wrench. It is difficult to rotate at the apex of the piston, but it can be rotated.
5. There is no problem with the disassembly of the starting motor. I feel that the power of the starting motor should not be enough. I plan to buy another one to try.
 
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