1996 Vulcan 800 Classic Carb Rebuild

[mikemarsh76]

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

[2WheelFun]

Hi Mike and welcome!

Take a look at the bikebandit microfiche and see what parts you'll need.

http://houseofmotorcycles.bikebandit...800B1%29US.asp

[mikemarsh76]

Thanks for the reply. I have already found the BikeBandit microfiche. However, the problem is that I don't know what parts I actually need to do a rebuild. Sure, I could order everything on the page, but that would cost alot. I'd really just like a recommendation as to which parts would suffice for a carb rebuild, taking into consideration that I'm also installing a Dynajet kit.

Once I know which parts to order, I can tear this puppy down and get it up and running again.

Thanks much,
MIKE

[yammahoppy]

Unless you have some type of airbox mod re-jetting is not necessary. Even if you do re-jet the dynojet kits are not correct. Have you removed the EPA stuff?

I am sure Woody will be by iin a little while. Also be sure to check out the Vulcan page of Russian Wolf. Has all the information you will ever need about your motor and bike. I cant find the url but someone will be along soon.....

[mikemarsh76]

As far as I know, the bike is completely stock except for the Jardine exhaust I just installed, and the K&N air filter that I inherited when purchased.

So you're telling me that an OEM carb rebuild is all that is necessary? I was under the impression that for aftermarket exhaust, a jet kit was pretty much required. Unless that you're saying the DynoJet kits are off for my particular bike model.

I'll wait for the arrival of Woody for that URL, can't wait to check out that site.

[yammahoppy]

If you have the stock airbox and epa equipment then all that should be required is an a/f screw adjustment maybe not even that with pipes. . As far as the DJ kits they do not provide the most accurate jets in the kit. I would just buy a rebuild kit from the dealer and start there.

I put V&H Cruzers on my 800 and did not re-jet. When I did my intake I removed all the stock airbox, epa equipment and then re-jetted and now have a hodge podge intake called The Okie Air System. Named after a guy on another board. It uses different parts from several manufacturers to make up the kit. My bike dynoed after the intake at 58rwh and 48rwtqe.

[yammahoppy]

Ok I found the link

http://www.angelfire.com/ak5/russwolf/

[mikemarsh76]

Oh....... my........ God....... I am in heaven right now after getting this link. Any spare time I thought I had just went out the window. I'm going to be busy removing the EPA equipment, Grampsizing the airbox, jetting the carb, switching out the tail and head lights, and swapping out the seat for a Mustang.

By the way, the rubber lines coming from the handlebars (which used to be gray I think), are now corroded and an ugly shade of red. I want to use some stainless steel or chrome braided cable to cover this up. Can anybody recommend a good place to find cable like this, or is Ebay the way to go?

Thanks so much everybody, hopefully I'll be able to contribute once I've dived into working on my Vulcan.

MIKE

[bluestringer]

Follow RW's info on rejetting and doing an air mod. The Okie Air is the way to go, but there is not a PDF on that as of yet. Before doing a carb rebuild, check the floats, sounds like they are stuck causing the leaking gas. Also, after you get it running, add a little seafoam to the tank and hit the rev limiter a couple of times.

[woodchucks800]

Welcome to the site Mike. I wouldn't think about a complete rebuild because like Blue said it's more than likely your float sticking. Just give it a good cleaning while your in there rejetting and grampsizing. You'll stay busy reading RW's site because theres plenty to read about on the 800.

[mikemarsh76]

Nice, I'm glad that a complete rebuild is most likely unecessary. Ripping apart my airbox sounds like a much better use of my time!

I'll keep in touch.

MIKE

[yammahoppy]

Originally Posted by bluestringer

Follow RW's info on rejetting and doing an air mod. The Okie Air is the way to go, but there is not a PDF on that as of yet. Before doing a carb rebuild, check the floats, sounds like they are stuck causing the leaking gas. Also, after you get it running, add a little seafoam to the tank and hit the rev limiter a couple of times.

THE OAS is as simple as re-jetting, installing an adapter then installing a spacer and then the Dragtron. It is not really that hard. The EPA removal and re-jetting is the tough part. It will definantly wake up the bike though......


Blue,

Have you had your bike dynoed yet with the Hi-5?.....

[bluestringer]

Originally Posted by yammahoppy

THE OAS is as simple as re-jetting, installing an adapter then installing a spacer and then the Dragtron. It is not really that hard. The EPA removal and re-jetting is the tough part. It will definantly wake up the bike though......


Blue,

Have you had your bike dynoed yet with the Hi-5?.....

Not yet. When we were at the Iron Angels Rally a few weeks ago, they had a dyno setup, but I didn't find it till we were getting ready to leave, and the wife didn't want to wait, so I had to pass it up. But there is another rally in October, and I will catch it then.

[woodchucks800]

Originally Posted by bluestringer

Not yet. When we were at the Iron Angels Rally a few weeks ago, they had a dyno setup, but I didn't find it till we were getting ready to leave, and the wife didn't want to wait, so I had to pass it up. But there is another rally in October, and I will catch it then.

Well how's the H-5 doing Blue? I know you guys over on Delphi were having a few minor problems but it sounds like you have got it figured out? I'll be seeing Okie on Friday ,do you want me to smack him for calling you hard headed? ( Can I hide out at your place until he quits looking for me afterwards? he's a pretty big guy)

[bluestringer]

Originally Posted by woodchucks800

Well how's the H-5 doing Blue? I know you guys over on Delphi were having a few minor problems but it sounds like you have got it figured out? I'll be seeing Okie on Friday ,do you want me to smack him for calling you hard headed? ( Can I hide out at your place until he quits looking for me afterwards? he's a pretty big guy)

I like it. Performance is great. Some were having problems with it sticking out too far, but I've got use to it and it doesn't bother me. I like the looks, next to the OAS, it's one of the best looking ones. I was hoping for a little better gas mileage, but I'm getting about the same as I was with the stock setup, so I can't complain. Hehe, yea, slap ole Okie up side the head, but you better be a fast runner cause he is a bigun.

[yammahoppy]

Originally Posted by woodchucks800

Well how's the H-5 doing Blue? I know you guys over on Delphi were having a few minor problems but it sounds like you have got it figured out? I'll be seeing Okie on Friday ,do you want me to smack him for calling you hard headed? ( Can I hide out at your place until he quits looking for me afterwards? he's a pretty big guy)

Thats one thing about Nate I like, he dont pull punches...... Woody tell him thanks for me for all the help he has given the guys intalling the OAS...... I bet you can out run him..... Maybe not on the bike but deffinatly on foot.....

[mikemarsh76]

Hi everybody-

Since my last post, I removed the carb, cleaned it out (there was some nasty gunk in the float chamber), removed the EPA equipment, Grampsized the airbox and installed a Dynojet kit. I had already installed Jardine drag pipes a while back.

I reassembled, and it fired right up nicely. The idle was a bit off, but nothing major. However, after a couple of seconds the carb had backed up and fuel started pouring out of the airbox. I'm thinking that possibly my fuel line is clogged up, and when I restarted more junk found its way to my carb.

Does anyone have any idea what in the hell might be going on here? I'm going to tear it down again tomorrow, but I'll listen to any advice people might have. I'd like to make tomorrow the last time I have to take it apart.

Thanks everyone!!

MIKE

[yammahoppy]

sounds like there may be some gunk in the tank.

[mikemarsh76]

Got the carb opened again, and its clean as a whistle. I'm thinking that there may be a problem with the float valve needle. Since it runs just fine until the carb floods, this may be the answer. Now, I just have to search around to figure out how to remove the damn float from the assembly. (I'm kind of a newbie when it comes to working on these, so being cautious and well-informed surely helps my cause)

MIKE

[USMVMC FL2]

Hey Marsh, I'm in the same boat. Have been having issues with my '01 800a carb flooding even going down the road. I have 2" Cobra drags on it and I'm in the middle of stripping out the EPA crap and getting rid of the stock airbox. Anyone have any advice on what jets/needle to run with this configuration? I'm also putting the beltdrive conversion on it. ANY help is GREATLY appreciated!!!!! Thanks guys! Angus