Vulcan 800 Bobber Project

[MikeGoodwin]

So today I moved my kill switch and starter button to the side cover. It was pretty easy and for the first time on this project something worked out on the first try. I also gutted all of the EPA junk but I have some questions for those of you that have done it. Do I cap the nipples for the vacuum system and EPA stuff on the carb?

Edit: I forgot to mention that I have the California model and there was a hose going from the canister under the side cover to the carb.

[goddarddr]

I capped the 2 nipples on the cylinders, and on the carb the one toward the front I caped after installing small tank, keep the air vent hose on the rear side of carb, if you have stock air box the crank case vent hose vents into it stays.

[MikeGoodwin]

Thanks dave. I have one more question for you. When you removed your thermostat, what did you do with the small hose that runs from the thermostat back to right in front of the swingarm somewhere. I can't tell where it goes or if I need it any more.

Have you still been getting some good weather up there? Hows the bike riding?

[goddarddr]

it stays, i tried to remove it when i did anti freeze comes out some. it connects to the overflow resevior tank. what I did was cut it off short. its tucked in out of site front of the swing arm but a little lower than top of the ignition key gizmo. when I went to the mustang tank, I removed the thermo with Rat's advise, rode last summer very hot no thermo or fan = no troubles like Rat said he had been doing it for years. looks alot better, wish there was to a way to hide that ugly heater hose.
I rode to work yesterday, its 70 clear, bike is running great, its Fast & Fun, I reouted some wiring by drilling some holes in the battery box with rubber gromets routed wires into juice box, I love that tiny battery provides lots of space for electics, I would like to look at my bike and not see any electric stuff im gettin there

[Rowdy1]

Mike, you do have to keep that small hose. I did the same thing Dave did with that hose. There is a wire holder behind the rear cylinder to the right of the key switch. I just cut the hose off and pushed it into that wire holder. I made the mistake of pulling it loose before I realized what it did. Don't do that! Its kinda a pain to get it back on, and all the while coolant is leaking out all over the place!

Bike looks great, by the way! That tank will look really good when you get it mounted right.

[MikeGoodwin]

Thanks for the advice guys. Maybe ya'll can help with this one. So I got my tank mounted and took it for a ride today but only made it about a mile from the house before it puttered and died. It started back up a couple times but wouldn't stay running. I finally killed the battery trying to start it up and had to walk it back. Anybody have any ideas of what may be wrong? I have a few but i'm not too sure. I did just leave the airbox off like shadders did and used the stock air cleaner so it may be a fuel/air mixture problem. I also have a long fuel line with a filter so that may be the problem but it looks like it's getting fuel. Any suggestions would be greatly appreciated because I'm pretty bummed that it's not rideable.

[squeeb]

I know a few people have had problems using inline filters. Sometimes they look like they are flowing ok but they really aren't. I'd start there.

[goddarddr]

is your gas cap vented?sounds like it ain't gettin fuel, what does no airbox but just a filter look like??

[Alley Rat]

I was thinking the same thing about the gas cap. Is your tanked vented through the cap or from a hose coming out the bottom.

[goddarddr]

don't know about the sporty, my mustang tank the only thing coming out of the bottom is the fuel line, so I have a vented cap
I have heard of trouble like yours because the cap vent was clogged. Hey Rat did you get your bars?

[MikeGoodwin]

Thanks for the replies guys. I bought a vented cap but my tank does have a vent on the bottom. I just left it open and didn't run a hose or anything. I also had my fuel line run kinda long so I shortened it up a bit and removed the inline filter. I don't know if that could have been the problem because the gas had to go back up to reach the carb inlet. It seems to be flowing fine now since I shortened it and removed the filter. I haven't had a chance to fire it up yet since my battery is off getting a charge. I will update when I get it back tonight. In the meantime, here's some new pics.

[goddarddr]

really looks good. its got that "TUFF" look with those black wheels fat tires.
I like the length of those pipes
stock air box ???????????

[ragekage]

oh man. looking so good. i wanna be friends with it.

[MikeGoodwin]

Thanks for the compliments fellas. I am digging the mean look. Dave, the air cleaner is the next thing to go. I just need to scrape together the cash to get it and rejet the carb. And the best news of this post is that my bike is running now. Got my battery back in and she fired right up first try with the shorter fuel line. I rode about 15 miles around town without a problem. Thanks for all of the helpful advice fellas.

So what's the word on the bobber ride this summer??

[goddarddr]

JULY 30 we r having my birthday party,cookout,band and all my Bobber friends are invited. lots of good day rides in country, canoe the Harpeth river just 3 mi from my house, check your calenders

[mumbles]

Man I was gone for a while and you've done alot of progress on your scoot Mike. She's looking great man.
Maybe a small air cleaner like on the old hot rod cars will complete the look.

[ragekage]

ust typed you a long post, then lost it. now you get the short version.
many pics. of moving the handlebar electrics please.

just curious if many pics were taken of this process or not...

[Thullan]

Definitely one of the better 800's I've seen in a long time, good job on that one.

[MikeGoodwin]

I'll add it to my calendar dave. Yeah mumbles, I've done quite a bit in the last couple weeks. I have some ideas for air cleaners. it's gonna be the next thing I do. I didn't take many pics while I was doing it but I can snap some and explain what I did if you'd like, ragekage. Thanks for the kind words thullan.

I do have a problem with the bike. I rode for about an hour last night and it ran fine. When I put it up I left the petcock open and didn't discover it until this morning. It started up and I made it down the road before it started acting up. It started putting again like it wasn't getting gas. I had to pull the choke for it to stay running so I could get it back home. I think I read somewhere that I need to leave it on choke longer since I removed the thermostat so that may be the problem. Any thoughts as to what may be wrong?

Something else that I noticed that may be causing the problem is that my fuel line only stays about half full of gas even when it was running. I don't know if you can see it but the line only has gas in it up to just above the red cap in the picture. Is this normal?

[dsc522758]

MikeGoodwin,

Up here in Arlington and was wondering if you still have your old parts? I was curious about 4 srews that are near the rear fender. They are usually removed when one installs saddle bags and are where the brackets install at. I don't have the orig. screws. See attached pic.