I think I have a problem with my front forks, but I am not as technical as I would like to be with bikes. I can work on any car, but I am learning slowly with bikes...

As for the problem at hand:

1996 Kawasaki Vulcan 800A Cruiser
bought at 24,800 in June 2006
25,500 miles currently

When I am cruising down the street, most noticable at 35-50 MPH, the front end seems to bounce. I think the fork seals need to be redone and oil replaced. It rides just fine on the highway at 70 MPH. Anybody have any ideas if I am on the right track before I try to tear into it?

PS: I am pushing 250 lbs, 6'2"
The gentleman that owned it before me could not have weighed 180-190 after dinner. He never noticed any bouncing or dipping in the front end.

Hi.
I've never ridden a vulcan, but I know a bit about bikes, you say it's bouncing? I'd check to see if the tyre is on the wheel properly, check the beading. Check is the tyre pressure too
If you think it might be the seals, then how's to check them.
Firstly clean the staunceon (the part that fits into the yolks).
Then put on the front brake and push down on the handlebars, compressing the forks.
Then check the stancheon again, if there are lines of oil on the stancheon, it would show the leak there.
Hope that helps
Si
:074
My Webpages

I am going to get the wheel checked to make sure it is aligned properly, but yes it dips or bounces or vibrates very badly around 35-45 MPH. I had a friend look at it, and they were the ones that recommended I redo the fork seals. I have not worked a bike intensively, so I am scared to jump in and redo it, but I think I am going to tackle it next weekend anyways. Just hope I can get it all back together. I am going to order the parts tomorrow. So if anybody has any tips and or tricks on Fork Seal Replacement, I am all ears.

Hmm, I don't know if I got the fork seal photo's I did the last time. I'll have to go through all of my footage to see if I still have them.
I'll run through it roughly for you here if I can.
Like I said before though, I've not worked on that particular model. So there might be a few small descrepances.
Remove the wheel, the calipers mudguard (fender) etc from the forks, then Remove the forks from the yolks. (loosen the clamp bolts)
Undo the caps from the top of the forks carefuly,they have springs underneath and they have been known to smack you in the face when you get to the end of the thread. Don't forget that the forks contain oil too, so either keep the forks upright when you do this. It will let you know how much oil is in each leg too. They should hold the same in each, if not, you will know it was leaking. If they are both the same then you don't have a seal problem.
If there the same type I've worked on before, then pour the old oil away (properly), then turn the forks upside down. there should be a allen bolt which is inside above the axel (spindle). When you undo those bolts you should be able to remove the stauncon from the base of the forks. Keep an eye on all the internal seals to make they don't get damaged, or lost. Keep them in a place where dirt n grit can't get into them too
Now remover the dust caps. Then the circlip this is what holds the seals in place and fits into a groove on the inside of the lower part of the fork.
Finnaly remove the old seal.
Now get the new seals into place, making sure any writing is visable on the top.
Then replace the circlip, and next slide the staunchon back into place.
Then replace the springs and internal seals into the lower part of the fork leg and do up the allen bolt and tighten.
Next replace the dust cap.
I usualy replae the fork legs into the machine and redo the clamp bolts.
Next thing is to replace the oil level right. Youl have to find how much oil should be in each leg. You should be able to get the infomation from you local dealer, it is very important to get the right amount, and to make sure that both legs have the same amount of oil in each as the bike will want to to turn left or right rather wanting to go in a streight line.
When you have the right amount of oil in each, replace the caps. This will be quite hard as you'll havve to compress the springs to get them in, again be careful, they can bite.
FInaly replace wheel etc.
I've got to say here, for legal reasons, that I'll take no resposability if you get it
wrong.
I'll be putting the whole thing onto my main website, sometime, with photo's But you'll have to wait for that.
Hope that helps though.
:074 :kbv
Si
My Webpages

Thanks a lot. I will try to take pictures as I work on it. I will probably set up my camcorder and record it so I can go back if I am not sure of anything going back together correctly. If it all goes well, I will send you the video and see if you can use any of it to help with your "How To."

Well, I had trouble getting the bike off the ground. Not being a Avid Motorcycle Repairman, I went ahead and let the local shop do it to the tune of $200 plus $100 in parts.

However, I am still having quite a bit of vibration/bouncing in the front end. It acts like the rear end of a car with bad shocks would when you pressed down on it. It bounces slowly. I can not notice it at highway speeds, but I figure that is just because the wind is pounding me. I am putting my windshield back on today, and I will go from there. What else might be causing the slight bouncing in the front end? I tried recommended tire pressure, max and minimum. Neither seemed to change the problem.

Something else I have noticed, when I slow down and hold the clutch, it makes some odd sounds like something is not properly oiled. I thought it was the chain, but that seems fine. I sure as hell hope my engine is not having problems. I guess I could tighten the clutch some and see if it is tapping.

hi mate, just a thought is your front brake sticking on you may not feel it at high speeds. i dont no what sort of brakes are on your bike so it may not be that...is it the front end bouncing or is it the rear shocks if there worn that can have an effect on the handling to? or have yor head bearings gone as this can sometimes make the front flex under braking .. any way just some more food for thought

tuddy :074

I payed a little more attention on the way home. Here is what I found. The bouncing has degraded, after I added my windshield back on, seems more like a slight vibration. Living in Texas, it may work itself out and bounce me straight. :)

But the other issue I noticed, sounds like my chain clicking or might be pulling in odd cycles making the front act as if it were bouncing? I noticed both about the same time, but the wind noise made it hard to decipher. Now with the windshield I can hear more.

Hi Bro,I've been a bit busy lately, and I'd missed a few of the updates on this subject until now. thanks of the offer of the photo's they would have been cool.
I'm glad you got some help to do the fork seals, and I hear you still have a vibration problem, although not as bad as it was..
I've never heard of front bounce coming from a chain before. If it's clicking though, I'd replace it as that usualy means damage to at least one of the links.
The only reason I've had front bounce has been from tyres not correctly fitted or once I had to replace a wheel after someone hit a kerb.
So if it's not any I don't know what can be causing the problem.
Hope you can find the problem, and let us know as it might help someone else in the future.
Have fun if you can and good luck
Si
My Webpages
PS Just remembered, check your headstock nuts. Might be that

I will just have to get in and check everything I can think of, and everything I can't.

I forgot to mention, I was wrong before. The noises I hear when I let of the throttle only click or clunk when I do not pull the clutch. If I let off the gas any, or cruise, it makes a click click click sound. That is what made me think of the chain or clutch. Either way, I am running low on money for fixing. I really do not want to park it, but I do not want to tear it up either. I am going to ask my brother if he knows any mechanics on the local fire department that might be able to look at it for me. A few of them ride older harleys, and are always having to piece them back together after long rides.

That sounds like a good plan.
Good luck

OK, I am getting a little more frustrated at this point. The bouncing or vibration I thought I felt seems more like a tugging now. If you have ever been towed in a automobile, when the vehicle in front pulling you takes off initially it kind of jerks you forward. This is the way it has seemed lately when riding my Vulcan. I had them tighten the chain, and it was nice and tight, but after a couple of months it has loosened a lot again. It had 3/4 -1 " of play at first, now it is closer to 2". I was told my chain was not in good shape and was going to have to replace it soon, but I had just forked out $300 for the forks. Has anybody ever heard of a chain causing a forward jerking motion? It seems as though if the throttle is not increasing, it does this. So if I am cruising, it does it. If I am accelerating, it is nice and smooth.

Also, when I slow down and let the bike slow itself down while downshifting, it still sounds like a click click click. I think that might also be the chain, possibly dragging on the case/cover that hides part of it? I am so lost, but I am determined to keep this bike.

Also, I am fully recovered from my stupid accident in my apartment. I laid the bike down after not seeing a speed bump. I was only going about 10 miles an hour, but there was loose gravel and when the front wheel hit the speed bump it jerked to the left and went down to the right. I jumped off when I noticed I was not going to be able to save it, and I took most of the beating. At such a slow speed, somehow my exhaust which is already screwed up and my windshield somehow took the fall. I had to replace a mirror.

Any help on the issues hopefully related to the chain is greatly appreciated.

done all I can for you, suggest you get in touch with www.vroc.org/ (Vulcan owners)
I got better things to do.
Si
http://www.dogdragons.com