Kawasaki Vulcan 800 Classic Service Manual

Kawasaki vulcan 800 classic service manual

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Also See for vn classic Service manual - pages Owner's manual - 55 pages Service manual - pages. Page of Go. Table of Contents. Show quick links.

Kawasaki vulcan 800 classic service manual

Hide Hide permanently. Motorcycle vulcan mean streak; vn mean streak pages. Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere. Page 6 Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance.

Video Sneak Peek Inside the Clymer 1995-2005 Vulcan 800 Motorcycle Repair Manual

Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done. Model Identification General Specifications Unit Conversion Table To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.

If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Overall Width mm Overall Height 1 mm Wheelbase 1 mm Road Clearance Brake Play Inspection The initial maintenance is vitally important and must not be neglected.

MO: Apply molybdenum disulfide oil mixture of the engine oil and molybdenum disulfide grease in a weight ratio Axial TIR 0.

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If the canister has any cracks or bad damage, replace it with a new one. Valve Clearance Standard: 0. Measure the clearance when engine is cold.

Kawasaki vulcan 800 classic service manual

Check present shim size. Match clearance in vertical column with present shim size in horizontal column. Install the shim specified where the lines intersect. This shim will give the proper clearance.

Example: Present shim is 2. Measured clearance is 0. If the gap is too wide, the clutch may not release fully.

Kawasaki vulcan 800 classic service manual

If the gap is too narrow, the clutch may not engage fully. If rim runout exceeds the service limit, check the hub bearings first.

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Replace them if they are damaged. If the problem is not due to the bearings, correct the rim warp runout.

Kawasaki vulcan 800 classic service manual

A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. If any measurement is less than the service limit, replace both shoes as a set. If it does not as specified, adjust the brake light timing.

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Brake Light Timing Standard: On after about 15 mm 0. Never reuse old brake fluid.

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Do not use fluid from a container that has been left unsealed or that has been open for a long time. If the steering too loose, tighten the stem nut a fraction of a turn. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap.

If cable movement is not free after lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable. Special Tools Throttle Grip and Cables Throttle Grip Free Play Inspection Throttle Grip Free Play Adjustment Throttle Cable Installation Throttle Cable Lubrication and Inspection Choke Cable Air Cleaner Case California Model 5.

Clamps California Model 6. If there is any irregularity, replace the choke cable. Turn the ignition switch OFF. Do not smoke.

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Make sure the area is well-ventilated and free from any source of flame or sparks; But if necessary set the pilot screw as follows. It will seat against the needle jet, pushing the end of the jet into the carburetor bore. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbure- tor with a cleaning solution.

If any of the O-rings or diaphragms are not in good con- dition, replace them.

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WARNING If dirt or dust is allowed to pass through into the carburetors, the throttle may become stuck, possi- bly causing an accident.

Check the tank cap breather also. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.

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Coolant Flow Chart Coolant Deterioration Inspection Coolant Level Inspection Coolant Draining Coolant Filling Pressure Testing Reserve Tank Removal Water Pump When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes. The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.

Radiator 5.


Water Pump Impeller 2. Fan Switch 6. To Crankcase 3. Water Temperature Sensor 7. From Rear Cylinder Head 4. Right Engine Cover 8.

Kawasaki vn 800 classic Service Manual

From Front Cylinder Head 9. Thermostat When the engine is cold, the thermostat is closed so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly.

If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system. If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage. Re- place the mechanical seal with a new one.

The radiator fan may start even if the ignition switch is off. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them.

Stop pumping and measure leak time at once. The relief valve must open within the specified range in the table below and the gauge hand must remain within the same range at least 6 seconds.