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Misfire

by Ed O'Gorman
(Port Charlotte, Fl)

I have a 2002 Kawasaki Vulcan 800 with 23,000 miles on it. Ever since I bought it it had a very rare what seemed like a misfire. The bike starts every time, idles perfectly and has great acceleration, and will run all day at speed with no problem. It's when I back off on the gas, I begin to get what sounds like a spit or a puff which I feel through the air filter cover, and the bike will start to chug and buck a bit till I give it more gas. Then it will run fine. I've had it to a repair shop, and they said it was caused by the ethanol in the gas, and to use sea foam which has done nothing. It is happening more frequently lately. Any advice on this problem would be greatly appreciated.
Ed O'Gorman

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Misfire

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Mar 13, 2010
Aftermarket Exhaust??
by: Quicklimegirl

Does your bike have an aftermarket exhaust? Has the stock filtration been changed to a more free-flowing unit or filter?

Often, when people add an aftermarket exhaust and/or a less restrictive air filter, the focus is on re-jetting with a larger main jet, or in the case of a FI bike, remapping. However, it's an inexact science that even shops don't get right the first or even 2nd time. With a carb bike, they may go up some sizes on the main jet and not touch the pilot jet; hence, when you back off the throttle, the part of the carb's fuel circuit controlling flow from closed to about 1/4 open (the pilot jet), which has been left the stock size, which is now too small with a freer flowing exhaust or filter is no longer up to the job.

I had the exact same problem with my '79 KZ650, it was because the previous owner didn't change the pilot jet to a larger size.

If you bike is fuel injected, the remapping needs to take into account all throttle position sensor adjustments and not just at the top end.

Mar 12, 2010
REQUEST
by: Anonymous

How about posting a pic of your 800 ~ I had a 2003 800 also.

Thanks,

suzzQ

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