Taking the "B.U." out of "B.U.B.F." - My Project: 1996 VN1500 C3, Vulcan L

[RogueJD]

BUBF: "Butt Ugly But Fast!"

The BUBF are 1500cc Vulcan 88, 88SE, and L Models (the A, B, and C series, respectively). These bikes are unique having a 1470 cc total displacement, 9:1 compression ratio, V-twin cylinders,4-speed transmission, shaft drive, and liquid cooled engine. Each cylinder is served by a Keihin CVK36 carburetor which contribute to the STOCK versions’ reputation as the fastest scoot in the Vulcan family.

At the beginning of October, 2008, I bought my first bike, a VN1500 C3, Vulcan L. I paid too much for it. NADA lists it at a retail of $2700'ish (on the high end.) With 18,000 miles, it was in generally good order (Squeaky clean engine, no leaks.) ...I paid 3500.

BEFORE:


This is how I purchased it. Pics do this bike justice, as the minor imperfections aren't visible.

The bike had been taken care of by the first owner, but the guy I bought it from (2nd owner) only rode it about 400 miles total, but managed to lay it down... twice.

The result was minor dents on both sides of the tank where the emblems hit. And a torn up handlebar where the windshield mounts scratched the chrome off.

The switch covers on the handlebars weren't properly tightened, so they sagged, and scratched the tank on one side.

Also, the guy advertised the bike as a 1998. I didn't pay close enough attention when I signed the title, but when I called for insurance, I was surprised to find that it was a 1996! If it were a dealership, I'd have done something about it, but since it was a private owner, I just went with it.

All things considered, I was happy to have my first bike.

PHASE 1: Strip it Down, Go Shopping!
I removed the following items:
* Windshield
* "Chrome" strips around Fenders, Fuel tank
* Tool bags
* Upper passenger pillon
* Sissy Bar
* Tail Light Assembly
* All emblems

I bought and installed the new handlebars (OEM "Drag" style.)
I had some tires mounted. I went a step or two larger than stock. 170mm, as opposed to the 150mm's.
I had to replace a part of the gear shifting mechanism. It wasn't as easy as it seems, as this was part of the Jardine forward controls. I ended up fabricating a replacement from an old shifter. Miracles can happen with only a hacksaw and a drill,


Now, I've got some parts on order, but this is the bike as it is now:






The way the fender was cut makes the bike look shorter than it really is. I'm not happy with the seat, fender, or tail light.

ON ORDER:
Fender: (The fender on my bike was cut, poorly, for a custom tail light assembly.)



Tail Light:
Tombstone by Kuryakyn


Seat:
Corbin Gunfighter: (Mine will be all black, no flames.)


I'd love to hear suggestions, comments, criticism, and general feedback.

During Phase 2, I'll hang all the newly ordered parts, and post some more pics.

Phase 3 is a paint job / dent removal (fuel tank). I'm 90% set on a Flat Black. I'm also considering wrapping the pipes. Truth is, I don't like "Flashy" chrome. Any feedback on this?

[RogueJD]

Been waiting on the fender for a few weeks now... Got it from a guy in Canada... Stupid Canada Post...

I'll keep you all updated when I get the parts hung.

[oldodge]

I never really agreed with the B.U. part anyway. So far looks good. Keep the updates coming.

[Hogbreath]

your improvments so far say you've got a good eye, I would like to see the cylinders, heads,and cases painted black, with highlighted fins, & is there anything that can be done with the air cleaners? Maybe flat black as well to blend in? anyway I think you have all ready improved the bikes looks 1000%, and the fender, and tail light and seat are all big wins! Great Job!

[keithert]

IMO, The only thing BU about the BUBF's are the air cleaner pods. Get rid of them!

[RogueJD]

Good idea about the air cleaners! Check this out. My pending purchase:

BLV-60431 - Cobra Kawasaki Vulcan 1500 Airbox Removal Kit

Cobra Kawasaki Vulcan 1500 Airbox Removal Kit

Kawasaki's 1500 Vulcan forced packaging demands upon its engineers that resulted in an air cleaner hung outside the bike, under the forward edge of the tank. None too stylish, if you ask us. Cobra's solution is this Airbox Removal Kit, available for the Vulcan 1500 A/B/C. A set of K&N filter pods attach to a manifold adapter so they fit out of sight and out of mind, and the Cobra Jet Kit makes sure this deep-lung monster carburets better than ever.

Before:


After!!:


I was considering ceramic coating the pipes, and engine / trans covers. I found this website. I gave 'em a call. Check out these prices! Not too shabby!:
Welcome to Performance Coatings

Come spring, I'm going to have a nice ride.

[keithert]

Much better!

[mr_ed]

Suscribed!! Dude your bike is gonna turn out awesome! I'm lovin every minute! I have a 1993 VN1500A and your project has breathed new life into my waning thoughts at customizing it!

Good luck and I'm anxiously waitin on the phase 2 photos!!

Ed

[RogueJD]

Sorry for not updating. Haven't been doing much because I'm in the process of moving.

I did get the fender in the mail, finally. Took almost 3 weeks to get it shipped from Canada.



I did a test fit, and was shocked to see the level of customization the previous owner did on the old fender. Seems like he chopped it, and made it sit lower on the fender supports.





I think I might have to shave it down a little. Not sure, yet. I want to get the Corbin seat in to see how it fits to the fender before I make any modifications.

She's got a huge, white butt now...


After I get moved in to my new house, I'll have a lot more workspace in the garage, so I'll likely rebuild the carbs, balance, and jet them for the "Ear Shave".

I found a really cool DIY link for the job that's a lot cheaper than the kit:
FAQ-Ext. Engine Mods

[DevilDogge]

Lookin good bro... I agree on wrapping the pipes. I wouldn't have gone for such tall risers on the bar, but I'm a tall guy. All black is always a safe choice, but I like to take chances myself... I'd say come up with a sweet paintjob out of your own mind. Keep the pics comin!! I always love the major mods.

[mr_ed]

Lookin good bro... I agree on wrapping the pipes. I wouldn't have gone for such tall risers on the bar, but I'm a tall guy. All black is always a safe choice, but I like to take chances myself... I'd say come up with a sweet paintjob out of your own mind. Keep the pics comin!! I always love the major mods.

I agree, except these bikes' fuel fill spot really sticks up off the top of the tank. If he'd gone with shorter risers he might have run into problems...like his bars hitting that chrome fairing on top o the tank...

[RogueJD]

Yep, those are OEM bars. I don't like the riding position that it puts me in, though.

If I'd have paid closer attention, I'd have bought different bars instead of replacing the damaged ones with OEM bars.

I was pretty much learning to ride when I bought the bars. Didn't have much of a basis for comparison.

@DevilDogge by comparison to your mod, mine is certainly no "major mod!"

I can't wait to see that thing finished!

//edit - Might be mistaken, but you're doing the frame extension, right?

[RogueJD]

Edit- Can a mod move this to the "Projects" forum?

Update:

I just need to vent. I've been pacing myself with this project, knowing that I've got time. I've decided to scrap the Corbin seat and opted for a custom seat. I was going to do the pan myself. I liked the way DevilDogge's looked.

Every pay period, I allocate about $200 or so for the bike. This pay period, I decided to go with a custom seat pan.

Until now, I've only mounted the fender loosely, just to get a feel for it's looks. I lowered the fender about 1" using spacers and I noticed that the fiberglass is badly warped to the left.

As low as I'd like to mount it, it would rub against the wheel on the right side.
I was pi$$ed!

Remember, it took about 3 weeks to get the fender from the guy in Canada. Now I have to ship it back to him, and wait for him to receive it before he sends a replacement.

Since I already bought the stuff for a seat pan (And a couple of other things) - I have to wait for a few weeks before I can start on the Carbs, or coating the pipes.

Oh well. At least I have time to do a little more research. I've never done carb work before, and I'm a little worried I'm gonna mess it up. -Thankfully, I'm organized, and I do a lot of forward planning.

Schedule:

1. Remove EPA / California Emissions crap.
2. Ear shave / Carb Rebuild.
3. I should have new fender in by this time, so I'll likely do the seat pan, and have it professionally upholstered
4. Ship pipes, Trans / Engine covers, Chrome suspension parts, fender struts for "Satin Black" coating.
5. Paint fenders Fuel Tank, Side Covers flat black.
6. Hope she starts up...

[mr_ed]

Sounds cool dude. Unforseen setback are a bummer huh?

[RogueJD]

Bad news for me. Not the fender.

...Seems like either the frame is bent, or the rear wheel is out of alignment. (If that's possible. I'll be posting another "Help me" thread about it.)

Man... I have to say. I'm really getting more. P.O.'ed about this bike as I go. I love it, but I hate the previous owner.

First, I buy it, thinking it was a 98 - only to pay closer attention to the title later to find out it was a 96. ...Then I find evidence that he layed it down a few times. ...Now this.

I'll update when I learn something.


//Edit: Update

Yep. Frame's bent. Son of a ...! Gonna take a 5 pound sledge to the frame extension with the bent fender rail mount. Might be able to rig it to work.

Problem is, it seems that the whole rear wheel is sitting closer to the right side of the bike. Can rear wheels be "Aligned" or is my frame that out of whack?

The difference is not that noticeable, but I'm a perfectionist. The frame at the rear fender rail mount is only about 0.5" off, but it's what's kicking the fender to the left.

[mr_ed]

Dang man that's a bummer. Sorry I can't help on aligning the frame...maybe a custom bike shop or bike repair shop would have a frame straightener? I don't know, do they even make chassis straighteners for bikes?

Hope you can get it worked out, it's gonna be a cool looking bike!

Ed

[mr_ed]

Quick question man...how much rise do you have on your handlebars?

[RogueJD]

Those bars are stock. The rise is needed to get over the hump in the middle of the fuel tank.

I don't like 'em, and I should have bought some aftermarket bars. I ended up getting stock ones from Kawasaki.com to replace the other damaged bars.

[bobkat]

Man this is so cool! Love this type of thread! The fender looks great , keep the pics coming!!!

[RogueJD]

Came Oh-so-close to selling the bike today. Wouldn't have gotten half of what I paid for it, but I wanted a new Jeep Wrangler, and they wanted a down-payment.

Got the Jeep. Get to keep the bike.

I literally was walking out of the dealership. I wasn't about to give up the bike. Dealer changed his mind in hurry.

Anway - Progress pics:

Started stripping more:



Pictures of my workspace. (Because I've seen some of your guys' garages, and I was like, "How the hell do they work in there...")