Engine rebuild question

RichERich323 · 01-30-2017, 02:20 PM

I bought a 96 1500 Classic from a buddy that had the infamous POG failure. I replaced the gear with the JOG and I'm in the process of reassembling the motor as the shop my buddy took it to started to disassemble the motor as part of their diagnosis process. I started putting the heads back on and noticed the port for the spark plug is blocking the cam chain. What am doing wrong? How do I get around that so I can put my cam chains back on?

jtascone · 01-30-2017, 03:03 PM

Not sure about the cam chain, but I thought the only year that had the infamous POG was the '99?

DragonLady58 · 01-30-2017, 03:27 PM

Theres a certain order that the engine is suppossed to assembled in. Get your Chiltons manual or whichever manual you have, look at your assembly order.
If you don't have a manual, get one.
I've been a mechanic for decades, even I have to use them for reference at times. I don't put the sparkplug tubes in till after the engine is static timed, cam marks aligned, chain tensioners set, etc.

Read up on it, the Pog here, or do a search:
http://vulcanbagger.com/forums/showt...dges+pump+gear

Pog in '96? Are you sure you got the year right?

**MAS Tequila** · 01-30-2017, 05:19 PM

Yes, you need to pull the plug 'tunnels' or sleeves in order to install or remove the chains.

They likely put them back in so as not to lose them.

MT

OldSchool · 01-30-2017, 06:11 PM

From the VROC Forums on the subject:

" All 1500 Vulcans, including 1500A, B,C models, Classics, and Nomads manufactured between 1987 and 1999 were built using plastic oil pump gears. Beginning with the 2000 model year, Kawasaki changed to a metal oil pump gear on all 1500 models. If you own a 2000 model year 1500, you do not have the problem. The 1500 Drifter is excepted from this as no Drifters, including the 1999 model, were ever built using the plastic oil pump gear. This issue pertains to the 1500 models only, not the 800, 750, or 500 models."

DragonLady58 · 01-30-2017, 07:59 PM

Quote:

Originally Posted by OldSchool

From the VROC Forums on the subject:

" All 1500 Vulcans, including 1500A, B,C models, Classics, and Nomads manufactured between 1987 and 1999 were built using plastic oil pump gears. Beginning with the 2000 model year, Kawasaki changed to a metal oil pump gear on all 1500 models. If you own a 2000 model year 1500, you do not have the problem. The 1500 Drifter is excepted from this as no Drifters, including the 1999 model, were ever built using the plastic oil pump gear. This issue pertains to the 1500 models only, not the 800, 750, or 500 models."

Learn something new every day! I knew the majority of the early models had them, cause people were wondering why those models didn't have problems, but the Nomads did....

**ringadingh** · 01-31-2017, 12:15 AM

The spark plug tubes unscrew from the head, then reinstall them after the head is on.

**vulcanscott** · 01-31-2017, 06:27 AM

Pog Failed on My 99 Classic at 21000 . Repaired it rode it 2 more seasons upgraded 2 the Nomad . V Scott

01-30-2017, 02:20 PM	#1
RichERich323 Jr. Member Join Date: Aug 2016 Posts: 2	Engine rebuild question I bought a 96 1500 Classic from a buddy that had the infamous POG failure. I replaced the gear with the JOG and I'm in the process of reassembling the motor as the shop my buddy took it to started to disassemble the motor as part of their diagnosis process. I started putting the heads back on and noticed the port for the spark plug is blocking the cam chain. What am doing wrong? How do I get around that so I can put my cam chains back on? Login or Register to Remove Ads
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01-30-2017, 03:27 PM	#3
DragonLady58 Sr. Member Join Date: Jul 2016 Location: Somewhere South of Alaska.... Posts: 2,351	Theres a certain order that the engine is suppossed to assembled in. Get your Chiltons manual or whichever manual you have, look at your assembly order. If you don't have a manual, get one. I've been a mechanic for decades, even I have to use them for reference at times. I don't put the sparkplug tubes in till after the engine is static timed, cam marks aligned, chain tensioners set, etc. Read up on it, the Pog here, or do a search: http://vulcanbagger.com/forums/showt...dges+pump+gear Pog in '96? Are you sure you got the year right? __________________ --------------------- Don't start no schit, there won't be no schit.... My Sarcasm is directly proportional to the amount of Stupidity involved --------------------- VBA#03239 VROC#37400 VRA --------------------- 2014 Vaquero 2001 Nomad FI 2003 Street Glide (sold) 1500 Meanie, fresh rebuild (sold) 90s BUBF Bobber (sold) 2001 UltraCycle FatPounder (Sold) 1975 HD ElectraGlide (Sold) 1982 Kawasaki Z1 Chopper (Sold) Suck It Up & Ride! Last edited by DragonLady58; 01-30-2017 at 03:51 PM.
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01-30-2017, 05:19 PM	#4
MAS Tequila Join Date: Jan 2009 Location: Psychiatric Ward FL Posts: 3,429	Yes, you need to pull the plug 'tunnels' or sleeves in order to install or remove the chains. They likely put them back in so as not to lose them. MT __________________ MT 2016 FLHP Psychiatric Ward FL VBA 936 Last edited by MAS Tequila; 01-30-2017 at 05:23 PM.
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01-30-2017, 06:11 PM	#5
OldSchool Sr. Member Join Date: Nov 2014 Location: Ballwin,MO. Posts: 1,542	From the VROC Forums on the subject: " All 1500 Vulcans, including 1500A, B,C models, Classics, and Nomads manufactured between 1987 and 1999 were built using plastic oil pump gears. Beginning with the 2000 model year, Kawasaki changed to a metal oil pump gear on all 1500 models. If you own a 2000 model year 1500, you do not have the problem. The 1500 Drifter is excepted from this as no Drifters, including the 1999 model, were ever built using the plastic oil pump gear. This issue pertains to the 1500 models only, not the 800, 750, or 500 models." __________________ Login or Register to Remove Ads
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01-31-2017, 12:15 AM	#7
ringadingh Join Date: Aug 2007 Location: Newmarket Ontario Canada Posts: 35,387	The spark plug tubes unscrew from the head, then reinstall them after the head is on. __________________ 2002 Nomad aka Bountyhunter VBA #27 VROC #18951
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01-30-2017, 03:03 PM	#2
jtascone Member Join Date: Jul 2015 Posts: 282	Not sure about the cam chain, but I thought the only year that had the infamous POG was the '99?
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01-31-2017, 06:27 AM	#8
vulcanscott Join Date: Oct 2013 Location: chandler okla Posts: 854	Pog Failed on My 99 Classic at 21000 . Repaired it rode it 2 more seasons upgraded 2 the Nomad . V Scott
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