Kawasaki VN800 (1996-2004) [200/405] Http manuals magnamaniac com

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• Http manuals magnamaniac com 1
• Kawasaki 1
• Motorcycle 1
• Service manual 1
• Vulcan 800 1
• Quick reference guide 2
• Http manuals magnamaniac com 3
• Http manuals magnamaniac com 4
• Kawasaki 4
• Motorcycle 4
• Service manual 4
• Vulcan 800 4
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• Read owner s manual before operating 5
• Emission control information 6
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• A warning 8
• Foreword 8
• How to use this manual 8
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• P manual magnamaniac 8
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• General information 10
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• Table of contents 10
• 2 general information 11
• Before servicing 11
• Especially note the following 11
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• Http v manuals magna iniac c m 11
• Before servicing 12
• General information 1 3 12
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• Two color electrical 12
• 4 general information 13
• Before servicing 13
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• Dimensions 16
• Engine 16
• General information 1 7 16
• General specifications 16
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• Performance 16
• Vn800 a1 a2 a3 a4 a5 16
• 8 general information 17
• General specifications 17
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• General information 1 9 18
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• Periodic maintenance chart 18
• 10 general information 19
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• Technical information sealed battery 19
• Caution 20
• General information 1 11 20
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• Technical information sealed battery 20
• 12 general information 21
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• Technical information sealed battery 21
• Awarning 22
• General information 1 13 22
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• Technical information sealed battery 22
• 14 general information__________________________________________ 23
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• Torque and locking agent 23
• General information 1 15 24
• Htt manuals magnamaniac om o 24
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• Torque and locking agent 24
• 16 general information 25
• Basic torque for general fasteners of frame parts ______________ _________ 25
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• Torque and locking agent 25
• General information 1 17 26
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• Special tools and sealant 26
• 18 general information 27
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• Special tools and sealant 27
• General information 1 19 28
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• Special tools and sealant 28
• 20 general information 29
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• Special tools and sealant 29
• General information 1 21 30
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• Special tools and sealant 30
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• 24 general information 33
• Cable wire and hose routing 33
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• Cable wire and hose routing 34
• General information 1 25 34
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• 26 general information 35
• Cable wire and hose routing 35
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• General information 1 27 36
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• 28 general information 37
• Cable wire and hose routing 37
• California model 37
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• 30 general information 39
• Cable wire and hose routing 39
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• Fuel system 40
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• Table of contents 40
• 2 fuel system 41
• Exploded view 41
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• 4 fuel system 43
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• Specifications 43
• Fuel system 2 5 44
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• Throttle grip and cables 44
• 6 fuel system 45
• Carburetor 45
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• Fuel system 2 7 46
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• 8 fuel system 47
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• Fuel system 2 9 48
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• 10 fuel system 49
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• Fuel system 2 11 50
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• 12 fuel system 51
• Air cleaner 51
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• Fuel system 2 13 52
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• 14 fuel system 53
• Fuel tank 53
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• Fuel system 2 15 54
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• 16 fuel system _______________________________________ 55
• Evaporative emission control system california model only 55
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• Fuel system 2 17 56
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• Cooling system 58
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• Table of contents 3 58
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• 4 cooling system 61
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• Specifications 61
• Coolant 62
• Cooling system 3 5 62
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• 6 cooling system 63
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• Cooling system 3 7 64
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• 8 cooling system 65
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• Water pump mechanical seal 65
• Cooling system 3 9 66
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• 10 cooling system 67
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• Radiator radiator fan 67
• Cooling system 3 11 68
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• Radiator cap inspection 68
• 12 cooling system 69
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• Thermostat 69
• Cooling system 3 13 70
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• Radiator fan switch water temperature sensor 70
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• Engine top end 72
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• Table of contents 72
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• Http manuals magnamaniac com 75
• Uals magn i maniac com 75
• Engine top end 4 5 76
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• 6 engine top end 77
• Clean air system 77
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• Cylinder head cover 78
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• 8 engfne top end 79
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• Camshaft camshaft chain 80
• Engine top end 4 9 80
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• 10 engine top end 81
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• Engine top end 4 11 82
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• 12 engine top end 83
• Camshaft chain tensioner 83
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• Engine top end 4 13 84
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• Rocker shaft rocker arm 84
• 14 engine top end 85
• Cylinder head 85
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• Engine top end 4 15 86
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• 16 engine top end 87
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• Engine top end 4 17 88
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• Valves 88
• 18 engine top end 89
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• Engine top end 4 19 90
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• 20 engine top end 91
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• Engine top end 4 21 92
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• 22 engine top end 93
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• Engine top end 4 23 94
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• Cylinder pistons 96
• Engine top end 4 25 96
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• 26 engine top end 97
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• Engine top end 4 29 100
• Http manuals magnamaniac com 100
• Muffler 100
• 30 engine top end 101
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• Clutch 102
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• Table of contents 102
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• Clutch 5 3 104
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• Specifications__________________________________________________ ____________________ 104
• 4 clutch 105
• Clutch lever and cable 105
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• Clutch 5 5 106
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• 6 clutch 107
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• Right engine cover 107
• Clutch 108
• Clutch 5 7 108
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• 8 clutch 109
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• Engine lubrication system 110
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• Table of contents 110
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• Http manuals magnamaniac com 112
• 4 engine lubrication system 113
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• Specifications 113
• Engine lubrication system 6 5 114
• Engine oil and oil fitter 114
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• 6 engine lubrication system 115
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• Oil pump oil pump drive chain ______________________ ___ 116
• ___________________engine lubrication system 6 7 116
• 8 engine lubrication system 117
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• Oil pressure measurement 117
• Engine lubrication system 6 9 118
• Http manuals magnamaniac com 118
• Oil pressure switch 118
• 10 engine lubrication system 119
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• Oil pipe relief valve 119
• Engine lubrication system 6 11 120
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• Http manuals magnamaniac com 121
• Engine removal installation 122
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• Table of contents 122
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• 4 engine removal installation 125
• Engine removal lnstallation 125
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• Engine removal installation 7 5 126
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• Http manuals magnamaniac com 127
• Crankshaft transmission 128
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• Table of contents 128
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• Http manuals magnamaniac com 130
• 4 crankshaft transmission 131
• Http manuals magnamaniac com 131
• Specifications 131
• Crankcase splitting 132
• Crankshaft transmission 8 5 132
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• 6 crankshaft transmission 133
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• Crankshaft transmission 8 7 134
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• 8 crankshaft transmission 135
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• Crankshaft connecting rods 136
• Crankshaft transmission 8 9 136
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• 10 crankshaft transmission 137
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• Crankshaft transmission 8 11 138
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• 12 crankshaft transmission 139
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• Balancer starter clutch 140
• Crankshaft transmission 8 13 140
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• 14 crankshaft transmission 141
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• Crankshaft transmission 8 15 142
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• 16 crankshaft transmission 143
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• Crankshaft transmission 8 17 144
• Http manuals magnamaniac com 144
• Torque limiter 144
• 18 crankshaft transmission 145
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• Primary gear 145
• Crankshaft transmission 8 19 146
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• Transmission 146
• 20 crankshaft transmission 147
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• Crankshaft transmission 8 21 148
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• 22 crankshaft transmission 149
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• Crankshaft transmission 8 23 150
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• Http manuals magnamaniac com 152
• Table of contents 152
• Wheels tires 152
• Http manuals magnamaniac com 153
• Http manuals magnamaniac com 154
• Specifications 154
• Wheels tires 9 3 154
• 4 wheels tires 155
• Http manuals magnamaniac com 155
• Wheels rims 155
• Http manuals magnamaniac com 156
• Wheels tires 9 5 156
• 6 wheels tires 157
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• Http manuals magimaniac com 158
• Http manuals magnamaniac com 158
• Wheels tires 9 7 158
• 8 wheels tires 159
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• Http manuals magnamaniac com 160
• Wheels tires 9 9 160
• 10 wheels tires 161
• Http manuals magnamaniac com 161
• Hub bearing 161
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• Wheels tires 9 11 162
• 12 wheels tires 163
• Http manuals magnamaniac com 163
• Speedometer gear 163
• Final drive 164
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• Table of contents 164
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• Final drive 10 3 166
• Http manuals magnamaniac com 166
• Specifications 166
• 4 final drive 167
• Drive chain 167
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• Final drive 10 5 168
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• 6 final drive 169
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• Final drive 10 7 170
• Http manuals magnamaniac com 170
• Sprocket coupling 170
• 8 final drive 171
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• Final drive 10 9 172
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• 10 final drive 173
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• Brakes 174
• Http manuals magnamaniac com 174
• Table of contents 174
• Http manuals magnamaniac com 175
• Http manuals magnamaniac com 176
• 4 brakes 177
• Http manuals magnamaniac com 177
• Specifications 177
• Brakes 11 5 178
• Calipers 178
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• 6 brakes 179
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• Brakes 11 7 180
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• 8 brakes 181
• Brake pads 181
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• Brakes 11 9 182
• Http manuals magnamaniac com 182
• Master cylinder 182
• 10 brakes 183
• Http manuals magnamaniac com 183
• Brake disc 184
• Brakes 11 11 184
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• 12 brakes 185
• Brake fluid 185
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• Brakes 11 13 186
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• 14 brakes 187
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• Brake hose 188
• Brakes 11 15 188
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• 16 brakes 189
• Brake pedal and cable 189
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• Brakes 11 17 190
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• 18 brakes 191
• Brake panel 191
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• Brakes 11 19 192
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• 20 brakes 193
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• Brakes 11 21 194
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• Http manuals magnamaniac com 195
• Http manuals magnamaniac com 196
• Suspension 196
• Table of contents 196
• 2 suspension 197
• Exploded view 197
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• Http manuals magnamaniac com 198
• 4 suspension 199
• Http manuals magnamaniac com 199
• Specifications 199
• Front fork 200
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• Suspension 12 5 200
• 6 suspension 201
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• Http manuals magnamaniac com 202
• Suspension 12 7 202
• 8 suspension 203
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• Suspension 12 9 204
• 10 suspension 205
• Http manuals magnamaniac com 205
• Rear shock absorber 205
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• S w i nga rm 206
• Suspension 12 11 206
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• Http manuals magnamaniac com 208
• Suspension 12 13 208
• Tie rod rocker arm 208
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• Steering 210
• Table of contents 210
• 2 steering 211
• Exploded view 211
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• Http manuals magnamaniac com 212
• Specifications 212
• Steering 13 3 212
• 4 steering 213
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• Steering 213
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• Steering 13 5 214
• Steering stem 214
• 6 steering 215
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• Steering 13 7 216
• 8 steering 217
• Handlebar 217
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• Table of contents 218
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• 4 frame 221
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• Frame 14 5 222
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• Side covers 222
• 6 frame___________________ 223
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• Storage box tool kit container 223
• Fenders 224
• Frame 14 7 224
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• 8 frame 225
• Battery case 225
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• Down tube rear frame 226
• Frame 14 9 226
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• Http manuals magnamaniac com 227
• Electrical system 228
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• Table of contents 228
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• Http manuals magnamaniac com 232
• Specifications 232
• _______________________________________________________ electrical system 15 5 232
• 6 electrical system 233
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• Parts location 233
• Electrical system 15 7 234
• Http manuals magnamaniac com 234
• Precautions______________________ ________________ 234
• 8 electrical system 235
• Electrical wiring 235
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• Battery 236
• Electrical system 15 9 236
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• 10 electrical system 237
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• Charging system 238
• Electrical system 15 11 238
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• 12 electrical system 239
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• Electrical system 15 13 240
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• 14 electrical system 241
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• Electrical system 15 15 242
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• 16 electrical system 243
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• Electrical system 15 17 244
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• 18 electrical system 245
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• Ignition system 245
• Electrical system 15 19 246
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• 20 electrical system 247
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• Electrical system 15 21 248
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• 22 electrical system 249
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• Electrical system 15 23 250
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• 24 electrical system 251
• Electric starter system 251
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• Electrical system 15 25 252
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• 26 electrical system 253
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• Electrical system 15 27 254
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• 28 electrical system 255
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• Electrical system 15 29 256
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• Lighting system 256
• 30 electrical system 257
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• Electrical system 15 31 258
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• 32 electrical system 259
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• Electrical system 15 33 260
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• Radiator fan system 260
• 34 electrical system 261
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• Meter instruments 261
• Electrical system 15 35 262
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• Switches and sensor 262
• 36 electrical system 263
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• Electrical system 15 37 264
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• Junction box 264
• 38 electrical system 265
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• Electrical system 15 39 266
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• 40 electrical system 267
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• Wiring diagram other than us canada and australia 273
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• Appendix 276
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• Table of contents 276
• 2 appendix 277
• Additional considerations for racing 277
• Carburetor 277
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• Spark plug 277
• Appendix 16 3 278
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• 4 appendix 279
• Engine doesn t start starting difficulty 279
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• Poor running at low speed 279
• Troubleshooting guide 279
• Appendix 16 5 280
• Clutch operation faulty 280
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• Over cooling 280
• Poor running or no power at high speed overheating 280
• 6 appendix 281
• Abnormal drive train noise 281
• Abnormal engine noise 281
• Abnormal frame noise 281
• Gear shifting faulty 281
• Http manuals magnamaniac com 281
• Oil pressure warning light goes on 281
• Appendix 16 7 282
• Battery trouble 282
• Brake doesn t hold 282
• Exhaust smokes excessively 282
• Handling and or stability unsatisfactory 282
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• 8 appendix 283
• Genera lubrication 283
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• Appendix 16 9 284
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• Nut boit and fastener tightness 284
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• Supplement 2000 2001 models 286
• Table of contents 286
• 2 supplement 2000 2001 models 287
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• 4 supplement 2000 2001 models 289
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• Supplement 2000 2001 models 17 5 290
• 6 supplement 2000 2001 models 291
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• Supplement 2000 2001 models 17 7 292
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• Http manuals magnamaniac com 296
• Supplement 2002 2003 models 296
• Supplement 2002 2003 models 18 1 296
• Table of contents 296
• 2 supplement 2002 2003 models 297
• Foreword 297
• Http manuals magnamaniac com 297
• General information 298
• General specifications 298
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• Supplement 2002 2003 models 18 3 298
• 4 supplement 2002 2003 models 299
• General information 299
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• General information 300
• Http manuals magnamaniac com 300
• Supplement 2002 2003 models 18 5 300
• Torque and locking agent 300
• 6 supplement 2002 2003 models 301
• Cable wire and hose routing 301
• General information 301
• Http manuals magnamaniac com 301
• Exploded view 302
• Fuel sytem 302
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• Supplement 2002 2003 models 18 7 302
• 8 supplement 2002 2003 models 303
• Fuel system 303
• Fuel sytem 303
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• Clutch 304
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• Specification 304
• Supplement 2002 2003 models 18 9 304
• 10 supplement 2002 2003 models 305
• Engine lubiication system 305
• Engine oil and oii filter 305
• Http manuals magnamaniac com 305
• Specifications 305
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• Supplement 2002 2003 models 18 11 306
• 12 supplement 2002 2003 models 307
• Engine removai lnstallation 307
• Engine removal lnstaliation 307
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• Http manuals magnamaniac com 308
• Specifications 308
• Supplement 2002 2003 models 18 13 308
• Wheels tires ___________________________ 308
• 14 supplement 2002 2003 models 309
• Exploded view 309
• Final drive 309
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• Final drive 310
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• Sprocket coupling 310
• Supplement 2002 2003 models 18 15 310
• 16 supplement 2002 2003 models 311
• Brakes 311
• Exploded view 311
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• Brakes 312
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• Supplement 2002 2003 models 18 17 312
• 18 supplement 2002 2003 models 313
• Brake disc 313
• Brakes 313
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• Master cylinder 313
• Exploded view 314
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• Supplement 2002 2003 models 18 19 314
• 20 supplement 2002 2003 models 315
• Electrical system 315
• Exploded view 315
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• Http manuals magnamaniac com 316
• Supplement 2004 model 316
• Supplement 2004 model 19 1 316
• Table of contents 316
• 2 supplement 2004 model 317
• Foreword 317
• Http manuals magnamaniac com 317
• General information 318
• General specifications 318
• Http manuals magnamaniac com 318
• Supplement 2004 model 19 3 318
• 4 supplement 2004 model 319
• General information 319
• Http manuals magnamaniac com 319
• Engine lublication system 320
• Engine oil and oil filter 320
• Http manuals magnamaniac com 320
• Specifications 320
• Supplement 2004 model 19 5 320
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• Electrical system 322
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• Supplement 2004 model 19 7 322
• 8 supplement 2004 model 323
• Electrical system 323
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• Specifications 323
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• Kawasaki 325
• Model application 325
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• Quick reference guide 328
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• Http manuals magnamaniac com 331
• Read owner s manual before operating 331
• A maladjustment of vehicle components such that the emission standards are exceeded b use of replacement parts or accessories which adversely affect the performance or 332
• C addition of components or accessories that result in the vehicle exceeding the standards d permanently removing disconnecting or rendering inoperative any component or element 332
• Durability of the motorcycle 332
• Elements of design in order to perform maintenance 332
• Emission control information 332
• Has been generally 332
• Http manuals magnamaniac com 332
• Interpreted as follows 332
• Of design of the emission control systems 332
• Tampering could include 332
• Tampering does not include the temporary removal or rendering inoperative of devices or 332
• The phrase remove or render inoperative any device or element of design 332
• Http manuals magnamaniac com 333
• Tampering with noise control system prohibited 333
• Foreword 334
• How to use this manual 334
• Http manuals magnamaniac com 334
• Http manuals magnamaniac com 335
• General information 336
• General information 1 1 336
• Http manuals magnamaniac com 336
• Table of contents 336
• 2 general information 337
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• General information 1 3 338
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• 4 general information 339
• General specifications 339
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• General information 1 5 340
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SUSPENSION 12 5 Front Fork Front Fork Removal each fork leg Remove Front Wheel see Wheels Tires chapter Front Fender A see Frame chapter Caliper B see Brakes chapter Clamp C Loosen Turn Signal Light Clamp Bolt A Front Fork Clamp Bolts B With a twisting motion work the fork leg down and out Front Fork Installation Install the fork so that the top end A of the inner tube is flush with the upper surface of the steering stem head Tighten the lower fork clamp bolt and fork top bolt Torque Front Fork Clamp Bolt Lower 34 N m 3 5 kg m 25 ft lb Front Fork Clamp Bolt Upper 20 N m 2 0 kg m 14 5 ft lb Install the removed parts see appropriate chapters Fork OH Change Remove the front fork see Front Fork Removal Push down A the top plug B to remove the ring C and then remove the ring and top plug Remove Collar A Spring Seat B Fork Spring C Drain the fork oil into a suitable container http manuals magnamaniac com http manuals magnamaniac com