Motorcycle Repair: stator and exhaust on 92 vulcan750, kawasaki vulcan 750, exhaust gaskets

Question
I took my bike (1992 Kawasaki Vulcan 750)to a shop because the battery was dead, and died again after 2 days on the new battery.  They said it was the rectifier, under the battery case.  They charged me $156 for the part, and $110 for labor.  But it still lost power again and wouldn't start after one and a half days.  So I took it back and they said it was the stator.  Another $156.  He said he has to move the whole motor, and it would cost $300 for labor costs.  Is that too much?  Anyways, do  you think I can do it with the Clymer Shop manual?  And what about new pipes?  I bought a brand new full exhaust system, and I didn't know if I could just take off the old and put the new on.  I know they must take new gaskets like cars do, but what else.  Please advise, any help will be much appreciated.  

Gabriel

Answer
Hi Gabriel,

I certainly wouldn't let the shop make any further repairs. They are not very thorough, to say the least.

The engine must be removed from the frame because the left frame down-tube prohibits access to lower altenator case cover screws and removal of the cover.

Parts that must be removed and reinstalled:
Entire exhaust
Carburetors (difficult)
Airbox and duct work
Ignition coils
Electrical connections
Final drive (front)
Cooling system
Foot pegs
Clutch & throttle cables
Fluids must be drained and replaced
Exhaust gaskets must be replaced


I'm doing the same job on the same model in my shop. It's alot of work. $300 is about what I charge to do the same. The shop is likely going on Kawasaki's flat-rate time table.

The task can be done at home. Clymer manuals can be difficult to understand. They lack clarity. Kawasaki service manuals are better. You could try the task, but I know you'll experience difficulty. Having a good facitily and proper tools will make the task easier. No Kawasaki "special tools" are needed, though air tools make the difference. You'll need a torque wrench.

It's a great opportunity to change the exhaust. I think two new exhaust gaskets cost me $3 each. Get them from Bike Bandit. "www.bikebandit.com" When the website opens, click "OEM Parts" and select year, make, model from the drop down menus that follow.

Visit the Vulcan Riders Owners Club website: "www.vroc.com" They have an excellent tech section.

Respectfully,
Mark Shively