1996 kawasaki VN 800 Vulcan Classic - Answered Questions & Fixed issues

There is a starter clutch which has a gear and a one-way Spragg. The starter gear should engage the gear inside the case; the Spragg ensures that the gear will engage with the starter is turning in a specific direction, but free wheels when the engine is running. If the gear inside the case is engaging the starter, the Spragg may be broken. In that case you will need to replace the one way Spragg. Replacing the Spragg is a major PITA!

Losing fuel pressure for some reason. Change filter, Check hoses.

35 lb front and rear.

if you have to ask......just kidding, get a manual from your dealer. step by step instructions for anything that goes wrong with your bike

What model do you own? Many bikes have easy access to the plugs, some Japanese Bikes have a plastic plate covering the plugs.

hesitation be caused by a clogged high speed jet. I would remove the float bowl and clean the jets thoroughly with carb cleaner spray.

Motorcycle Sparkplug Maintenace Guide Motorcycle Maintenance Guide Try this link to know more. Gopakumar Gopalan Google

remove clutch case and make sure all parts are correctly aligned and no bits left inside !

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.

Go to Babbitt's online you can order a new factory carburetor.

The Carburetor is flooding. The only thing thatwill cause a flood problem is the float needle is not seating properly in theneedle seat. The Carburetor will need to be removed to replace the Needle and Floatassembly. After instillation the float level will need to be checked, andadjusted if required. This is a little tricky, and would be quite lengthy to explainhear. Short version is, the needle is a two part piece, having a spring loadedpiston located in the needle, the neoprene needle tip will need to be seated inthe seat, the spring loaded piston in the needle will need to remain uncompressed, in other words not pushedinto the needle what so ever. With the float tang just touching the top of theuncompressed needle piston. To do this hold the carburetor housing in aposition to accomplish the the above configuration. Measure from the carburetorhousing gasket surface to the highest point of the float drum. The measurement specificationsare (14.5 to 18.5 mm) or (0.57" to 0.72" in). Make sure the float pin rotates

If the 1997 Vulcan 800A has the same rear finder side chrometrim as the 1996 Vulcan 800B the instillation will be as follows. I can't rememberfor sure if you need to remove the chrome trim or maybe only loosen it enoughto run the wires. Remove the seat, for safety remove the negative batterycable, loosen or remove the chrome side trim, trace the light wires to wherethey plug into. Each side will have a separate plug in location. Each wire hasa color, one will be striped the other will be a solid color, when reconnectingthe wires make sure they are connected back to the proper color.

could be you spark plugs need replacing

general rule of thumb is to go up about 10 jet sizes,unfortunately it is a bit of trial and error,and you may have to swap out diferrent sizes to get the bike running right,(jets are quite cheap though)but first step about 10 sizes from standard,your local dealer should be able to tell you what jets are in it and supply replacements,if you change to a hgh flow aftermarket air filter you may have to change jet sizes again as changing the filter may effect the mixture ratio in the carbs,,hope this helps

The fuse box is under the seat.You have to remove the battery and its the back box on the left side jest pull it out.

todays bikes run perfect on Regular, which can be from 87 to 90 in some cases. you would not damage the bike by using pump gas like super or premium but anything higher may cause problems. but there is no advantage to using premium

Hi, apparently the vulcan 1500 has been FI since 1991 through till 2008

You have several possibilities. Burned out light bulb, blown fuse, bad switch, loose wire connection and a broken wire. Track it down with a multimeter.

This sounds like a carb overflowing this normaly occures when the float valve sticks, you will have to remove the bottom of the offending carb, remove and clean the float valve assembly inc seating

the minimum for a battery should be 12.4 volts,, its probably not getting the amps that are needed, replace the battery