Kawasaki VN800 (1996-2004) [252/405] 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
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• Kawasaki 4
• Motorcycle 4
• Service manual 4
• Vulcan 800 4
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• A warning 8
• Foreword 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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• 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
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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
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• Special tools and sealant 29
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• Special tools and sealant 30
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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
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• Throttle grip and cables 44
• 6 fuel system 45
• Carburetor 45
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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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• 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
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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
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• Radiator cap inspection 68
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• Thermostat 69
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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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• Uals magn i maniac com 75
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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
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• 10 engine top end 81
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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
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• 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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• 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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• Http manuals magnamaniac com 116
• 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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• Table of contents 152
• Wheels tires 152
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• Http manuals magnamaniac com 154
• Specifications 154
• Wheels tires 9 3 154
• 4 wheels tires 155
• Http manuals magnamaniac com 155
• Wheels rims 155
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• 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
• Http manuals magnamaniac com 165
• 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
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• 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
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• Master cylinder 182
• 10 brakes 183
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• 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
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• 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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• 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
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• 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
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• 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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• 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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• Supplement 2004 model 316
• Supplement 2004 model 19 1 316
• Table of contents 316
• 2 supplement 2004 model 317
• Foreword 317
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• General information 318
• General specifications 318
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• Supplement 2004 model 19 3 318
• 4 supplement 2004 model 319
• General information 319
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• Engine lublication system 320
• Engine oil and oil filter 320
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• 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
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• Http manuals magnamaniac com 335
• General information 336
• General information 1 1 336
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• 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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ELECTRICAL SYSTEM 15 25 Starter Motor Assembly Install the terminal assembly in the yoke Tighten the terminal nut Torque Starter Motor Terminal Nut 11 N m 1 1 kg m 95 In lb Fit the projection A of the brush plate into the yoke notch BJ co After holding the springs A with suitable washers B insert the brushes as shown Insert the armature and then pull out the washers to release the springs Fit the long tongue A of the bush plate into the end cover groove BL When the yoke brush plate and end covers are properly assembled the lines A on the yoke and cover should be aligned Tighten the through bolts Torque Starter Motor Through Bolts 4 9 N m 0 50 kg m 43 in lb Brush Inspection Measure the length A of each brush If any is worn down to the service limit replace the brush plate B and the terminal assembly CJ Starter Motor Brush Length Standard 12 0 12 5 mm Service Limit 5 5 mm http manuals magnamaniac com http manuals magnamaniac com