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Discussion Starter #1 (Edited)
My initial service on the 900C

I started servicing the bike I bought by doing the brakes.
The brake thread: http://www.vulcanforums.com/forums/49-vulcan-900/251529-so-i-did-my-brakes-yesterday.html

Continuing to go through this bike I bought, I am starting the engine service.
I installed some new spark plugs on Saturday.
I did not have the special plug wrench (I do not have the OEM kit) but I have enough tools that it did not matter.
The front one is a little more cramped but there is enough space to work just the same.

I used the torque wrench mostly because of the crush washer on the plug. Otherwise, I would probably have done it by feel.

Next comes oil+ filter and engine coolant change.
I need to read up on the valve adjustment issue first to see if I need to get in further.
 

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for engine coolant i went to a honda new car dealer where they also sell parts and got a jug of honda type-2 50/50 pre-mix blue good for aluminum motors
 

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Discussion Starter #4 (Edited)
I did a bit more this weekend.

I changed the oil and filter.
I installed a new air filter.
I changed the coolant.
I installed a new license plate light. The previous owner had removed it and changed the plate location a little.
 

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Discussion Starter #5
I put in some exhaust gaskets.
I installed new front turn signals. The previous owner had removed them.
 

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Discussion Starter #6
I removed the grips and ordered some new ones. These ones were too big for my hands to be comfortable.
The new Kuryakn ones should be here today.

I will get two new tires ordered this week. That will be the next step to get those mounted.
 

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Valve check is not required until 15K miles. There is a very good 2 part video on youtube that takes you through the process.

WB
 

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Discussion Starter #8 (Edited)
My tires showed up this morning. I quickly pulled the wheels and took them all to the shop to have them mounted and balanced. I will get them back tonight or tomorrow.
One step closer....
 

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Living The Dream
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Wanna come by my place when your done? I got a stator job, new bars to install, and new saddle bags coming, and absolutely no time or energy to get it done. Help a brother out man? LOL
 

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Discussion Starter #10
I got the grips on. Easy job.
I got my wheels and tires back but have not had time to mount them yet.
 

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Discussion Starter #11
My wheel seals will get in sometime this coming week. They were on back order.

This morning, I removed the front belt pulley and freshened up the Moly grease and put that back together.

Tonight, I stripped the forks in preparation for the seals and dust seals that I ordered. The oil was pretty black. It was DEFINITELY the right choice to strip them all the way down and wash out the tubes and parts. They are staged and ready for the replacement rubber parts that I ordered.

I ordered a 30mm socket for the nut at the top of the stem. With the forks out, it makes sense to inspect and put new grease on the stem bearings.
I will put the pictures up at some point.
 

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Discussion Starter #12
So here is the front Pulley set.
It was bone dry but in perfect shape.

I am very glad I pulled it.
I got a chance to inspect the seal in the transmission case.
I polished the spacer collar where the seal rides while I had it out.
 

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Discussion Starter #13 (Edited)
Torque it up.
Stake the washer against the nut.
Button it up.

I would encourage anyone with an older bike to do this, just for the chance to check/change the seal and spacing collar as needed.
 

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Discussion Starter #14 (Edited)
So I stripped the forks.
Again, I am so glad I decided to do this.
The oil was pretty black.
There was a bit of moisture entering at the chrome plastic caps which is to be expected, once you take them off and actually look at them. No harm done.
30 seconds on the wire wheel to clean and shine up those top plugs.
 

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Discussion Starter #15 (Edited)
I got them stripped fully.
I washed and inspected everything.
They are ready to put back together when the seals and O-Rings arrive.
This is not a difficult job at all. Anyone should give it a go.

It just goes to show that maintenance is more than an oil change.
 

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Torque it up.
Stake the washer against the nut.
Button it up.

I would encourage anyone with an older bike to do this, just for the chance to check/change the seal and spacing collar as needed.
Is that a 57001-1672 Rotor Holder?????? Just got one off ebay and did the same stuff. Be sure to wipe off the excess grease from behind the pulley on the 1/2" of spacer sticking out or it will fling everywhere.

I like the way you work.
 

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Discussion Starter #17
Is that a 57001-1672 Rotor Holder?????? Just got one off ebay and did the same stuff. Be sure to wipe off the excess grease from behind the pulley on the 1/2" of spacer sticking out or it will fling everywhere.

I like the way you work.
Thanks Du-Rron. Yes, That is the tool. Apparently the handle is a separate Part number :) Not a problem though.
I did wipe everything after the photos were taken.

Kevin
 

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Discussion Starter #18 (Edited)
This was what I meant about the water seeping in under the plastic chrome caps on the tubes.
You can see the grooves that allow them to compress into the tube.
They could have been better designed.
It is worth looking under those if you have an older bike or it sits outside.
 

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Discussion Starter #19 (Edited)
In preparation for putting the forks back together, I made a seal driver.

I went to Lowes and got a PVC adapter. $3 and 20 minutes later...
I put it in the lathe and turned it and bored it to make a seal driver for the fork legs.
The shoulder is the correct depth and diameter to seat the oil seal properly.
The other end of it can seat the dust cover seals too.
 

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Discussion Starter #20 (Edited)
With the forks out I decided to pull the stem.
Again, I am glad that I did.
Lower bearing needs to be replaced. I ordered both.

Bottom Seal: $6.88
Kawasaki SEAL-OIL,XMHE36X52X4J Part # 92049-1162

Bottom Bearing and Race: $27.56
Kawasaki BRG,ROLLER,HR320/28XJ Part # 92116-1009

Top Bearing and Race w/seal: $32.89
Kawasaki BEARING,STEERING STEM Part # 92047-017

Locking tab washer: $3.23
Kawasaki WASHER,CLAW,25.5X34X0 Part # 92200-0353

I removed the old bearings and races and cleaned it up (stem and frame) for the new ones to arrive.
I will add a grease fitting to the frame so that I will never do this job again.

I am happy to be going through this bike pretty thoroughly. I know that I will feel better knowing what is under me when I am done.
It also means that I am almost certainly going to pull the swingarm to inspect and lube once I get the front end back together next week.
 

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