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VN800 (1996-2004)
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Kawasaki VN800 (1996-2004) [270/405] 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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Http manuals magnamaniac com 7
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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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
Engine top end 4 7 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
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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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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
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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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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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Crankshaft transmission 128
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Table of contents 128
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4 crankshaft transmission 131
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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
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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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Specifications 154
Wheels tires 9 3 154
4 wheels tires 155
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Wheels rims 155
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Wheels tires 9 5 156
6 wheels tires 157
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Wheels tires 9 7 158
8 wheels tires 159
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Wheels tires 9 9 160
10 wheels tires 161
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Hub bearing 161
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Wheels tires 9 11 162
12 wheels tires 163
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Speedometer gear 163
Final drive 164
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Table of contents 164
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Final drive 10 3 166
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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
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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
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4 brakes 177
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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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Suspension 196
Table of contents 196
2 suspension 197
Exploded view 197
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4 suspension 199
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Specifications 199
Front fork 200
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Suspension 12 5 200
6 suspension 201
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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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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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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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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
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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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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
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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
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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
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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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Http manua ls gnamaniac com 325
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Kawasaki 325
Model application 325
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Quick reference guide 328
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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
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Tampering with noise control system prohibited 333
Foreword 334
How to use this manual 334
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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
General specifications 340
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6 general information 341
H hwi manuafs m i agnamaniac com 341
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Periodic maintenance chart us and canada 341
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Periodic maintenance chart other than us and canada 342
_____________________________________ general information 1 7 342
8 general information 343
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General information 1 9 344
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Manuals magnama 344
Niac com 344
Torque and locking agent 344
10 general information 345
Basic torque for genera fasteners 345
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Torque and locking agent 345
Wheels tires 346
2 wheels tires 347
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Specifications 347
Final drive 348
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Ot con 348
2 final drive 349
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Specifications 349
Brakes 350
2 brakes 351
Exploded view 351
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Manuals magnamaniac com 351
Brakes 11 3 352
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Specifications 352
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Suspension 354
2 suspension 355
Exploded view 355
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Specifications 356
Suspension 12 3 356
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2 frame 359
Exploded view 359
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Electrical system 360
2 electrical system 361
Electrical system 15 3 362
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4 electrical system 363
Electrical system 15 5 364
6 electrical system 365
Electrical system 15 7 366
8 electrical system ______________ 367
Electrical system 15 9 368
Http manuals magnamaniac com 369
Http manuals magnamaniac com 370
Supplement 2000 2001 models 370
Table of contents 370
Foreword 371
How to use this manual 371
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General information 372
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Model identification 372
General specifications 373
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General specifications 374
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Fuel system specifications 375
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Http manuals magnamani 377
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10 supplement 2000 2001 models 379
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Vn800 b5 b6 wiring diagram australia 379
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Supplement 2000 2001 models 16 11 380
12 supplement 2000 2001 models 381
Horn butt 381
Http manuals magnamaniac com 381
I hl r r 381
P park 381
Vn800 b5 b6 wiring diagram other than u s a canada and australia 381
Http manuals magnamaniac com 383
Http manuals magnamaniac com 384
Supplement 2002 model 384
Supplement 2002 model 17 1 384
Table of contents 384
2 supplement 2002 model 385
Foreword 385
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General information 386
General specifications 386
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Supplement 2002 model 17 3 386
4 supplement 2002 model 387
General information 387
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General information 388
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Supplement 2002 model 17 5 388
Torque and locking agent 388
6 supplement 2002 model 389
Genera information 389
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Exploded view 390
Fuel system 390
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Supplement 2002 model 17 7 390
8 supplement 2002 model 391
Fuel system 391
Fuel tank 391
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Clutch 392
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Specifications 392
Supplement 2002 model 17 9 392
10 supplement 2002 model 393
Engine lubrication system 393
Engine oil and oil filter 393
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Specifications 393
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Supplement 2002 model 17 11 394
12 supplement 2002 model 395
Engine removal lnstallation 395
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Exploded view 396
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Supplement 2002 model 17 13 396
Wheels tires 396
14 supplement 2002 model 397
Exploded view 397
Final drive 397
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Final drive 398
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Sprocket coupling 398
_______________________________ supplement 2002 model 17 15 398
16 supplement 2002 model 399
Brakes 399
Exploded view 399
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Brakes 400
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Supplement 2002 model 17 17 400
18 supplement 2002 model______________________________ 401
Brake disc 401
Brakes 401
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Exploded view 402
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Supplement 2002 model 17 19 402
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Http manuals magnamaniac com 404
Http manuals magnamaniac com 405
Kawasaki 405
Model application 405
Part no 99924 1199 56 405

Kawasaki VN800 (1996-2004) [270/405] Http manuals magnamaniac com

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