2003 kawasaki VN 800 Vulcan Classic - Answered Questions & Fixed issues

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.

DO NOT jump with a automobile!! TOO MUCH AMPERAGE!! Get a new battery, have the solenoid checked, have the starter checked (ALL by a professional!!) its one of these three..

One vacuum line

Set the engine to top dead center for number one cylinder. As you remove the rocker covers, take pictures of their position. When removing cam gears and heads DO NOT ROTATE the engine even the slightest amount. You can then reassemble the engine without re timing it. If you move it you will need a shop manual and some time to get it right. Good luck.

IT IS IN YOUR SECONDARY KEYS.. WITH A METAL TAG WITH THE NUMBERS.

WHEN YOU BOUGHT THE BIKE IT CAME WITH A LITTLE METAL TAG WITH SOME NUMBERS... THAT IS YOUR KEY NUMBER REPLACEMENT

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

Hi,
It seems your clutch engage too earley to compensate by the gas.
Adjust the clutch so that when you release the clutch handle, it will have time to pull and add some gas.
Hope that helps you out!
Thanks for using Fixya!

BEHIND THE REAR CYLINDER ON THE TOP OF ENGINE CASE IT IS ROUND HELD IN PLACE BY 2 BOLTS

Please check these things before you start taking stuff apart: Gas in Tank? Fuel valve turned on? Kill switch in the Run position?

the petrol is fairly old any possibly no good so i would change it and once you have if still the same re adjust the air mixture screws if its running to rich with the petrol being that old that wasin in i would also advise removing and cleaning the carbs

these type manifolds are made of a metal base and a rubber joint. the rubber is hermetically sealed to the metal part. over time, this seal can go bad causing a leak that is undetectable by the average person. if you say you have replaced carb and sprayed around the boot with a pickup in rpm's, i would replace the boots abd orings! this should solve your leand condition.

Hi
If it is the correct part then the wires should be the same colours as the ones to the connector
If it is just that the connectors have different layouts then remove each pin & replace in correct positions or just chop the plug & socket off & join respective wires with crimp terminals
As long as it has the correct number of wires going to the right places it should be alright as they all have similar specifications

I hope this helps, if so please mark as helpful.
Positive comments always appreciated

Ride Safe
Bike-Doc

you check the oil level by looking at the sight glass it should be 1/2 to 3/4 full on the sight glass or on your filler plug there is a level at the bottom where the oil should touch

I will bet the chain is talking to you. I can hear its' voice from here... it's saying " Please adjust me , please adjust me, and lubricate me also." Chains can be such a pain at times. :)

Please rate this answer. Thanks keakins2! :)

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.

May be your bikes clutch plates are bad, try to replace the clutch plates it might work...

Question edited to add MAKER. Question moved from Computers category. https://www.google.com/search?q=Kawasaki+Vulcan+parts ..

Of course. The bolt is in the middle of the splined shaft and holds the sprocket as well. Some have a hole where you insert a rod to lock the sprocket, or you can put the bike in 1st Gear and give the breaker bar a sharp tap with a lump hammer. Or you can jam the chain somewhere back by the back sprocket, for instance putting a ratchet strap through the rear forks and the wheel, or you can get someone to apply the rear brake.

Vin numbers give all the info you need. Call a dealership and they can tell you. If there is a data plate, it also has the model on it.