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mikemarsh76 · 05-10-2006

Hey everybody, I'm really glad I found this site! There's lots of information here that I'm looking forward to reading through.

I have a question, and I'm hoping someone can point me in the right direction. I bought a 1996 Vulcan Classic 800 a few months ago, and from the get go, I had problems with *sputtering* during acceleration when the engine was cold. I had to keep it choked until it warmed up, otherwise it would almost stall when accelerating.

I quickly grew tired of the stock exhaust, and bought a set of Jardine slash-cut drag pipes on Ebay. Installed them, and went for a nice (and loud) drive up the San Diego coast. I parked it, and then the next day when I started it, the thing would turn over but not fire up. After turning it for a few seconds, gas started POURING out of the carburetor and air cleaner housing drain. Followed that up by draining the carb, waiting a day for it to dry out, and then I tried starting it again. Same result.

What I believe I need to do is rebuild the carburetor. I'd like to do a complete rebuild, but I'm unsure as to what parts I need to do this. I'm very good at reading instructions from the shop manual, so if somebody could tell me what parts I need, I'd have no problem doing the installation. I'd like to err on the side of caution, so if there's a part that may or may not need replacing, I'd like to go ahead and replace it.

Another note is that I ordered a DynaJet kit and I'll be installing this concurrently with the total rebuild. So I'd rather not order OEM parts that will be replaced by parts in the jet kit.

I look forward to hearing from anybody on this forum! I finally made some time to work on my cycle in the upcoming weeks, and I can't wait to get back on the road.

Thanks,
MIKE

05-10-2006	#1 (permalink)
mikemarsh76 Newbie Join Date: May 2006 Posts: 9	1996 Vulcan 800 Classic Carb Rebuild Hey everybody, I'm really glad I found this site! There's lots of information here that I'm looking forward to reading through. I have a question, and I'm hoping someone can point me in the right direction. I bought a 1996 Vulcan Classic 800 a few months ago, and from the get go, I had problems with sputtering during acceleration when the engine was cold. I had to keep it choked until it warmed up, otherwise it would almost stall when accelerating. I quickly grew tired of the stock exhaust, and bought a set of Jardine slash-cut drag pipes on Ebay. Installed them, and went for a nice (and loud) drive up the San Diego coast. I parked it, and then the next day when I started it, the thing would turn over but not fire up. After turning it for a few seconds, gas started POURING out of the carburetor and air cleaner housing drain. Followed that up by draining the carb, waiting a day for it to dry out, and then I tried starting it again. Same result. What I believe I need to do is rebuild the carburetor. I'd like to do a complete rebuild, but I'm unsure as to what parts I need to do this. I'm very good at reading instructions from the shop manual, so if somebody could tell me what parts I need, I'd have no problem doing the installation. I'd like to err on the side of caution, so if there's a part that may or may not need replacing, I'd like to go ahead and replace it. Another note is that I ordered a DynaJet kit and I'll be installing this concurrently with the total rebuild. So I'd rather not order OEM parts that will be replaced by parts in the jet kit. I look forward to hearing from anybody on this forum! I finally made some time to work on my cycle in the upcoming weeks, and I can't wait to get back on the road. Thanks, MIKE