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Carlos Perez Posted on Jun 12, 2017

2003 Kawasaki Vulcan 800 classic has a fuel leak from the carburetor

My Kawasaki 2003 Vulcan 800 classic has a fuel leak from the carburetor and every time that I put gas in the tank it starts leaking again what is the problem on this and how to solve it

1 Answer

Randall Box

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  • Posted on Nov 09, 2021
Randall Box
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More than likely you have a bad fuel petcock. No fuel should go from tank to carb without the engine running because the fuel is pulled by vacuum. Remove line from petcock an have it set to on or reserve position and if fuel comes out it is bad, and let's the fuel continue to flow to the carb and seep into the engine oil also. Mine was bad and had my oil thin as water with all the gas in it. Wonder it didn't wash a bearing out of the engine. Check and drain oil immediately if the petcock is bad.

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Anonymous

  • 2336 Answers
  • Posted on Nov 10, 2008

SOURCE: remove a gas tank

there are 2 bolts at the front of the seat, takeoff the seat, unsrew the bolts. that is the only thing holding it on. push the tank forward a bit, then lift up. there are breather tubes under the tank. be careful, they are difficult to get back on depending on the length. there are 2 bolts at the front of the seat, takeoff the seat, unsrew the bolts. that is the only thing holding it on. push the tank forward a bit, then lift up. there are breather tubes under the tank. be careful, they are difficult to get back on depending on the length.

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Anonymous

  • 2336 Answers
  • Posted on Nov 10, 2008

SOURCE: gas tank

I'm pretty sure it does. I own a 1995 Vulcan and I bought a 2003 tank and looked at the mounting brackets and fuel connections all looked to be the same - but don't put this in stone. I haven't been able to put it on yet because it's still out being painted. There should be no difference in the fuel tank mounts from 1996-1005, but as always, check with a professional if this information is critical.

Anonymous

  • 2336 Answers
  • Posted on Nov 10, 2008

SOURCE: no start

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

tombones

  • 3567 Answers
  • Posted on Mar 14, 2009

SOURCE: lifter adjustment

IF I recall correctly, the Kawasaki valves are adjusted by shims as opposed to a lock-down screw or hydraulic lifters. The shims come in different thicknesses. As the valve parts wear, a change in shims is how the valves are adjusted.

Knight 007

Murtaza Akberali Versi

  • 767 Answers
  • Posted on May 13, 2009

SOURCE: i just bought a 2004 vulcan classic 800 how do i

Try out the electrolysis way. please send me your email addy on [email protected] and i will send you the complete process wth illustration.
As for the fuel line, remove the line and blow it out wth high air -pressure.

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I have a 99 Kawasaki Vulcan classic one car bike why would the bike flood the back spark plugs and put gas in my air filter been trying to figure it out but I need help

Brandon, From Vulcan forum, one of the hoses that are hooked to the carb is a vent tube and may run up and under seat, if this hose is plugged or pinched it could cause similar issue to what you are experiencing. Links below discuss the issue you are presently having.
Check the attached links,instruction and guides,also you can also google (Kawasaki Vulcan flooding rear cylinders) for more info.
Good luck
"I hope this helped you out, if so let me know by pressing the helpful button. Check out some of my other posts if you need more tips and info."
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Any motorcycle parts dealer would be able to put you right on track. A Kawasaki parts department will be able to tell you as well.
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Didn't know they made a Vulcan 400.

BUT, if you meant a Vulcan 500, maybe this'll help:

http://www.bikebandit.com/houseofmotorcycles/1992-kawasaki-vulcan-500-en500a-fuel-evaporative-system/o/m150088sch55170
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Lifter adjustment

IF I recall correctly, the Kawasaki valves are adjusted by shims as opposed to a lock-down screw or hydraulic lifters. The shims come in different thicknesses. As the valve parts wear, a change in shims is how the valves are adjusted.
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