How-To: Kawasaki Vulcan VN800 carburetor clean & rebuild 1995-2006
I’ve put together an hour long VIDEO on how to properly clean and rebuild your Kawasaki Vulcan VN800 carburetor. The video walks you through the process step by step, and covers all models from 1995-2006. After purchasing the video, you can instantly stream it with unlimited views. Get your bike back on the road and save yourself at least $150 by doing it yourself!
Year, Make, Model
A 2001 was featured in the video, however models 1995-2006 are similar if not the same.
Symptoms
There are many reasons why a carb clean or rebuild is needed:
- Bike will only run on starting fluid (clogged jets)
- Bike takes forever to warm up and needs choke on to run better (jets partially clogged)
- Fuel leaking due to a stuck, dirty, or worn float needle (like the bike in video)
- Age. The rubber parts in a carburetor degrade over time. (Accelerator pump diaphragm, air cut off)
- Stale fuel. If you let your bike sit with untreated fuel, it will gunk up over time.
- Crankcase is overfilled and oil smells like fuel. (stuck float caused fuel to leak inside engine and bypass piston rings. Make sure you change the oil!)
Diagnosis
The owner of this bike told me that one day he walked into the garage and noticed fuel coming out the exhaust pipes and other areas, pooling under the bike. This is a classic symptom of the float needle causing the issue, whether stuck, dirty, or worn.
Tools
Here are links to some tools from Amazon that will make the job go much easier.
Extra long ball end allen keys
Vessel Megadora 980 Impacta P2x150 #2 JIS Cross Point Impact Screwdriver
Vessel 125943 908 P3x150 Impacta Screwdriver
Other Helpful Videos
If your carburetor still has the factory welch plug, watch this helpful video on how to remove it.
In the video, I mention DIY soda blasting. Here is everything you need to know on the subject.
If soda blasting is not your thing, check out the Chem Dip vs. Pinesol video.
Once you get the bike running, make sure to check for vacuum leaks. I initially did not have the boot tight enough. The clamp is a PITA to tighten.
Once the bike is up to operating temperature, and no vacuum leaks present, go ahead and tune the fuel screw. The video below explains how to do so.
Parts
I was only able to find OEM parts for this model, which is not a bad thing, however I feel they were quite expensive! Also, the float needle comes with the float, which I feel did not have to be replaced.
Comments
Has this blog post or video helped you in any way? Comment below and tell me about it!
I see in the first photo they are using an older style of lift. That bike would look great on one of our SL-30 Lifts. Check out our website at http://www.hmcindustries.com for more information on our lifts and other products.
Hey I am going to purchase your video, but do I really need the auxiliary fuel tank?
No, you can prop up the tank.
Ya kinda timelapsed through the info i came for. What the hell is the plastic piece called that is attached to the carb and the fuel line? Mine is cracking and I’m trying to replace but my manual does not explain it at all.
Plastic fuel elbow? Here is a video on how to replace it: https://youtu.be/_hcSG1j9yOE
I’m trying to purchase this video. I do not see a link for purchase.
Here is the direct link: https://gum.co/OrPk
I ran out of gas filled it up but now it will not send gas to the filter and pump why is it doing this
Verify that the petcock is flowing fuel.
Error 404 – Nothing Found
The page you are looking for could not be found.
this is what I found when I clicked on the service manual PDF
The service manual comes with full video tutorial.
Hi Matthew, I see my question has been erased somehow…
I bought a VN800 Bobber. When I shift from 1st to 2nd and open the gas handle there is a sort of “hickup” in the engine/torgue…not like the gear misses torgue.. but a “hickup forwards”… selles told me it had to do with the gasneedle(..(?!) … any idea?
Sounds like a lean condition. Can you send me a video? Any modifications to the bike?
I found and purchased this video to help fix the exact same issue that you opened with. Never took apart a carb before and this was easily worth it to get the step by step. Really appreciate the guidance!
After reassembly, is the vacuum piston supposed to move with the throttle? It moves freely when pushed up and down but I’m wondering how it moves in relation to the throttle. Worried I missed a step here
The CV slide does not move with the throttle. It moves based on engine vacuum.
Matt
I believe my 800 is running lean. Does the full video show the screw that controls the fuel/air mixture. I have watched the youtube version a few times as well as other videos on how to adjust but have not been able to identify the screw yet. Also, the previous owner installed a K&N filter, any reason that may cause the bike to run lean vs stock OEM filters?
Thanks.
Yes it shows removal and installation of the fuel screw. I have a separate video on tuning. The k&N filter element in stock airbox correct? They do flow a bit more over stock.
Do you have the video for replacing the carburetor? And if so, is it one for sale or do you have it uploaded to YouTube?
The full video includes everything.