Omar Khalid
The Kawasaki Vulcan 1500 Drifter is a motorcycle that was manufactured with a plastic oil pump gear. From 1987 to 1999, all Vulcan 1500 models, except the Drifter, were built with this plastic gear. The plastic gear was prone to failure, causing damage to the engine. As a result, Kawasaki changed the plastic gear to a metal one in 2000. This change addressed the issue, and Vulcan 1500 models produced after 2000, including the Drifter, feature a metal oil pump gear.
| Characteristics | Values |
|---|---|
| Year of production | 1987-1999 |
| Type of oil pump gear | Plastic |
| Models with plastic oil pump gear | All Vulcan 1500 models except the Drifter |
| Models without plastic oil pump gear | The Drifter |
| Issues with plastic oil pump gear | Intermittent clacking of lifters, breaking, failure to pump oil |
| Replacement options | Steel gear, JOG, OEM metal oil pump gear |
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What You'll Learn
- The 1987-1999 Kawasaki Vulcan 1500 models, except the Drifter, were built with plastic oil pump gears
- The plastic oil pump gear was changed to a metal one in 2000
- The plastic oil pump gear is prone to breaking and causing engine damage
- A replacement oil pump gear for a motorcycle engine can be installed using a keeper and screws
- Some Vulcan owners have experienced issues with the plastic oil gear, with some opting to replace it with a metal one
The 1987-1999 Kawasaki Vulcan 1500 models, except the Drifter, were built with plastic oil pump gears
The Kawasaki Vulcan 1500 is a powerful and popular motorcycle. However, some models have been known to experience issues with their oil pump gears. Specifically, certain models from the years 1987 to 1999, excluding the Drifter, were manufactured with plastic oil pump gears. This component has been identified as a weak point in the design, with several Vulcan 1500s suffering failures of these plastic gears, resulting in varying levels of engine damage.
The plastic oil pump gear, also referred to as the POG, is a critical part of the motorcycle's engine. When functioning correctly, it plays a vital role in ensuring the engine receives an adequate supply of oil for lubrication. However, due to the inherent limitations of plastic, these gears are susceptible to breakage over time. This can lead to catastrophic engine failure if not addressed promptly.
The issue of the plastic oil pump gear predominantly affects Vulcan 1500 models manufactured between 1987 and 1999. During this period, Kawasaki utilized plastic for the construction of these gears, which has since been recognized as a design flaw. The decision to use plastic was likely influenced by factors such as cost-effectiveness and ease of manufacturing. Unfortunately, this choice had unintended consequences, as the gears proved to be fragile and prone to failure.
The consequences of a broken plastic oil pump gear can be severe. When the gear breaks, it can result in a complete loss of oil pressure, causing the engine to seize up. This, in turn, can lead to extensive engine damage, requiring costly and time-consuming repairs. In some cases, the engine may need to be entirely replaced, incurring significant financial burdens on owners.
It is important to note that not all Vulcan 1500 models from this period are affected by the plastic oil pump gear issue. Notably, the Drifter variant was produced with a metal oil pump gear, avoiding the problems associated with its plastic counterpart. This exception highlights Kawasaki's recognition of the issue and their subsequent efforts to rectify it in specific models.
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The plastic oil pump gear was changed to a metal one in 2000
The Kawasaki Vulcan 1500, or VN1500, is a motorcycle that was manufactured with a plastic oil pump gear from 1987 through 1999. However, the Drifter model of the VN1500 was an exception and did not feature a plastic oil pump gear during this period. The plastic oil pump gear was prone to failure, causing varying degrees of damage to the engines of affected Vulcan 1500 motorcycles.
Due to the issues with the plastic oil pump gear, Kawasaki changed the material from plastic to metal in the year 2000. This change was implemented to address the frequent failures of the plastic gear, which had the potential to cause significant engine damage. The metal gear was designed to be more durable and resistant to breakage, ensuring the smooth operation of the motorcycle engine.
Owners of the VN1500 with plastic oil pump gears experienced issues such as intermittent clacking of the lifters, flashing oil lights, and sudden engine failures. These problems often led to costly repairs, with some owners reporting expenses exceeding the original purchase price of the motorcycle. To address these concerns, Kawasaki took responsibility and repaired every Vulcan in the United States that experienced a failure of the oil pump gear, regardless of warranty status.
The process of replacing the plastic oil pump gear with a metal one involves removing the plastic gear from its shaft and installing a keeper, which acts as a mounting base for the new metal gear. This procedure can be performed without removing the entire engine, making it a more feasible and cost-effective solution for affected motorcycle owners.
With the introduction of the metal oil pump gear in 2000, Kawasaki addressed a significant concern among VN1500 owners and improved the reliability and performance of their motorcycles. This change ensured that subsequent models, such as the 2001 Vulcan 1500 Classic, were equipped with a more durable and dependable oil pump gear.
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The plastic oil pump gear is prone to breaking and causing engine damage
From 1987 through 1999, all Kawasaki Vulcan 1500 models, except the Drifter, were built with a plastic oil pump gear. Plastic oil pump gears are prone to breaking and causing engine damage. This can be due to several reasons, including overheating, blockage in the oil pump, or debris.
Plastic oil pump gears are designed with a weak point so that they fail first rather than any other metallic gears. This is a safety choice by engineers to protect other components in the engine. However, if the weak point fails, the entire engine will fail shortly after.
To prevent engine damage, it is important to regularly check and maintain the plastic oil pump gear. This includes checking for any tight spots in the gear, which may indicate damage from metal particles, and cleaning and sanding the gear to remove any built-up debris.
If the plastic oil pump gear does break, it can be replaced with a steel gear. The process involves removing the gear from its shaft, inserting a keeper into the slots in the shaft, and then screwing the steel gear onto the keeper. This replacement method ensures that the engine can continue to function properly without the need for major repairs.
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A replacement oil pump gear for a motorcycle engine can be installed using a keeper and screws
From 1987 to 1999, all Kawasaki Vulcan 1500 models, except the Drifter, were built with a plastic oil pump gear. If the plastic oil pump gear in a motorcycle engine needs to be replaced, the process involves the following steps:
Removing the Old Gear:
First, the old plastic gear is removed from its shaft. This can be done using a small pair of locking pliers. It is important to be gentle during this step to avoid damaging the circlip inside the case on the shaft. If the gear does not break cleanly, a cutting tool can be used to cut slots in the remaining part of the gear, and screwdriver blades can be inserted to apply pressure and split it.
Inserting the Keeper:
Next, a keeper is inserted into the slots in the shaft that originally held the plastic gear. The keeper is a U-shaped object with arms and threaded screw holes. It is machined to fit snugly into the slots, with its flat surfaces engaging the slots and its curved surface mating with the shaft's curved surface. If the keeper does not fit, it can be thinned through sanding.
Mounting the New Gear:
Finally, a new steel gear is screwed onto the keeper, mounting it onto the shaft. The screws used can be of any suitable type, but it is recommended to use screws designed for a hexagonal wrench (Allen wrench).
This process allows for the replacement of the oil pump gear without direct engagement between the new gear and the shaft, simplifying the installation process.
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Some Vulcan owners have experienced issues with the plastic oil gear, with some opting to replace it with a metal one
The Kawasaki Vulcan 1500 is a powerful motorcycle that has been a popular choice for riders around the world. However, some models of the Vulcan 1500, specifically those manufactured between 1987 and 1999, have been known to experience issues with their plastic oil pump gears. This issue has caused concern among Vulcan owners, with some taking proactive measures to prevent potential problems.
The plastic oil pump gear, an essential component in the motorcycle's engine, has been found to be prone to failure in some Vulcan 1500 models. This failure can lead to significant engine damage and costly repairs. In response, many Vulcan owners have taken it upon themselves to address this issue by replacing the plastic gear with a metal one. This modification is done to prevent sudden breakdowns and the associated repair costs, which can often exceed the bike's value.
The process of replacing the plastic oil gear with a metal one involves carefully removing the original gear and installing a new metal gear onto the shaft. This procedure requires mechanical expertise and a set of specialised tools. Some owners choose to perform the replacement themselves, while others seek assistance from experienced mechanics or dealers.
One Vulcan owner shared their experience on an online forum, describing the sudden onset of an oil light flashing while riding their bike. Upon inspection by a Kawasaki dealer, it was confirmed that the plastic oil gear had indeed failed and needed to be replaced. The owner was informed that the engine would have to be removed and dismantled, resulting in a labour-intensive and costly repair.
Another owner, anticipating potential issues with the plastic oil gear, sought guidance from fellow riders on replacing it with a metal alternative. They were advised to either install a metal gear themselves or opt for a new motor, as the cost of both options would be comparable. The owner decided to find a fellow Kawasaki rider who could machine an OEM metal oil pump gear to fit their bike. This solution allowed them to retain the original metal shaft and provided peace of mind for future rides.
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Frequently asked questions
No, the VN1500 Drifter did not have a plastic oil gear. From 1987 through 1999, all Vulcan 1500 models, except the Drifter, were built with a plastic oil pump gear.
The VN1500 had a plastic oil gear from 1987 through 1999.
No, the 2001 VN1500 did not have a plastic oil gear. In 2000, Kawasaki changed the plastic gear to metal, so the 2001 model has a metal oil gear.
You can check if your VN1500 has a plastic oil gear by looking for the part in the Oil Pump section of the parts diagrams for your bike on Kawasaki.com.
