Vulcan 800 only start in neutral - VN 800 A Vulcan kawasaki Motorcycles

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Same thing happened on my 97 vn800. It's possible that your kickstand safety switch is stuck in place, making the bike think that the kickstand is still in the down position. Clean out the switch with some brake cleaner spray and then spray wd-40 on it. Move the kickstand up and down to further lubricate it. The switch will now smoothly move in and out instead of being stuck in one position. I bet that will solve your problem.

Instructions

1. Engine Problems
   • 1 Check the level of fuel in the gas tank if the engine stalls, misfires or will not start. Refill with unleaded gasoline if the fuel tank is empty.
     
   • 2 Examine the condition of the fuel if the gas tank has adequate levels. Gummy or watery fuel may be contaminated. Take the Vulcan 800 to a mechanic to have the fuel tank drained. Refill with fresh gasoline.
     
   • 3 Use the choke and try to restart the engine if the weather is cold. Move on to the next step if the engine still won't start or runs improperly.
     
   • 4 Remove the spark plugs from the Vulcan 800's two cylinders, located underneath the Vulcan's seat and front console: Carefully pull the spark plug cap from each, turning each spark plug counterclockwise with a spark plug wrench, and lift gently from each cylinder.
     
   • 5 Inspect the electrodes of each spark plug. Clean any carbon buildup with a sandblasting device or high-flash-point solvent and a wire-bristle brush.
     
   • 6 Replace the plugs with new NGK CR7EA or ND U22ESR-N spark plugs if the electrodes on the original appear burned, white and brittle or cracked.
     
   • 7 Set the spark plug gap between 0.028 and 0.032 inches. This gap measures the distance inside the hook at the end of the spark plug. To widen this gap, use a spark plug gap tool to pull the hook out gently to the desired gap. To shorten the gap, press the spark plug's hook against a firm, level surface.
     
   • 8 Restart the engine. If it still won't run properly, take the Vulcan 800 in for repairs.
     
   Starter Motor
   • 9 Check the engine stop switch located on the left handlebar if the starter motor won't work and the engine won't turn over. If it is in the "OFF" position, switch it to "ON" for regular operation.
     
   • 10 Check to ensure the clutch lever is pulled in and that the transmission is shifted to neutral.
     
   • 11 Check the main fuse, located underneath the Vulcan 800's seat near the rear tire. If the connection in the center of the fuse looks burned or broken, replace it with a 30A fuse.
     
   • 12 Check the battery, located under the Vulcan 800's seat. Unscrew the battery bracket bolts with a wrench, and remove the battery bracket. Remove the battery leads, first disconnecting the lead from the negative terminal and then the positive one. Carefully lift the battery out of its case.
     
   • 13 Clean any corrosion from the battery terminals using a wire-bristle brush. Clean any debris using a solution of 1 tbsp. of baking soda mixed with 1 cup of water.
     
   • 14 Charge the battery to 12 volts before reinstallation using a separately powered charger.
     
   • 15 Reinstall the battery, connecting the lead to the positive terminal first and the lead to the negative cable second. Put a light coat of grease on top of the battery terminal to prevent corrosion, and reinstall the bracket and seat.
     
   • 16 Operate the electric starter. Take the Vulcan 800 in for repairs if the engine still turns over slowly.
     
   Overheats
   • 17 Do not idle or operate at extremely low speeds for extended periods of time, as this can cause the engine to overheat.
     
   • 18 Check the engine oil levels by removing the cap and dipstick from the oil filler, located on the bottom left side of the Vulcan 800. Dry the dipstick with a shop rag, return it to the oil filler and remove it once more. Engine oil levels should be between the "H" and "L" marks on the dipstick. If not, refill with SAE 10W-40 engine oil.
     
   • 19 Check coolant levels in the reserve tank by situating the Vulcan 800 on a level surface and observing the visible level in the tank's transparent hose. Levels should be between the two marks on the side of the hose. Refill with a solution of distilled water and antifreeze if coolant levels are beneath the lowest mark.
     
   • 20 Restart the engine and take the Vulcan 800 in for inspection if it continues to overheat.
     

having to hold the clutch in and have the bike in neutral before it will start is more than likely a saftey feature from the manufacturer.

Sit at a traffic light till the temp reaches about 220, it should start about then. My fan has come on 3 times in 8 years.

Does it do anything when you turn the ignition switch? Perhaps the contacts inside aren't touching or are corroded? Let me know, good luck!

Have you checked all your safety switches? Kill switch, kickstand switch, neutral switch? What do the plugs look like---are they wet and smell like gas? Are you getting a nice blue spark across the electrode? Troubleshoot the basic stuff first to eliminate those possibilites.

the timing chains on the vulcan 800 are self adjusters, you do not need to manually adjust them.

Make sue\re to add fresh gasoline to the fuel tank and make sure it is entering thr carb.