Kawasaki Vulcan Manual
This Clymer motorcycle manual covers the Kawasaki Vulcan 800 Series for these model years: 1995-2005
1995-2005 KAWASAKI VN800A
1996-2005 KAWASAKI VN800B
Note: This manual does NOT cover the VN800C/E Drifter models
The Kawasaki Vulcan manual by Clymer is the best reference book for repair and service information for your Vulcan motorcycle. Every Clymer motorcycle service manual is written for the do-it-yourselfer as well as the experienced mechanic, Clymer motorcycle repair manuals are the cheapest way to keep your motorcycle running properly. Every Clymer motorcycle service manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the motorcycle covered. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail, accuracy and clarity to guide the reader through each service, troubleshooting and repair procedure.
The Kawasaki Vulcan manual includes the following chapter information:
QUICK REFERENCE DATA
CHAPTER ONE: GENERAL INFORMATION
Manual organization | Notes, cautions and warnings | Safety first | Service hints | Washing the bike | Special tips | Torque specifications | Fasteners | Lubricants | RTV gasket sealant | Gasket remover | Threadlocking compound | Expendable supplies | Serial numbers | Warning and information labels | Basic hand tools | Precision measuring tools | Special tools | Fabricating tools | Mechanic's tips | Ball bearing replacement | Seals | Riding safety | Storage
CHAPTER TWO: TROUBLESHOOTING
Operating requirements | Troubleshooting instruments | Starting the engine | Emergency troubleshooting | Engine starting troubleshooting | Engine performance | Engine noises | Engine lubrication | Clutch | Gearshift linkage | Transmission | Electrical troubleshooting | Test equipment | Basic test procedures | Electrical problems | Charging system troubleshooting | Ignition system troubleshooting | Starter system troubleshooting | Carburetor troubleshooting | Excessive vibration | Front suspension and steering | Brake problems
CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Routine inspection | Pre-ride inspection | Service intervals | Tires and wheels | Battery | New battery installation | Battery electrical cable connectors | Periodic lubrication | Periodic maintenance | Tune-up
CHAPTER FOUR: ENGINE UPPER END
Engine principles | Servicing engine in frame | Cylinder head cover | Camshaft | Rocker arms/rocker shaft | Cam chain and chain guides | Cylinder head | Cylinder head inspection | Cam chain tensioner body inspection | Cylinder block | Valves and valve components | Pistons and piston rings | Break-in
CHAPTER FIVE: ENGINE LOWER END
Engine | Oil pump | Primary drive gear | Balancer assembly and starter gears | Crankcase | Crankshaft and connecting rods | Break-in
CHAPTER SIX: CLUTCH
Clutch cable | Clutch cover | Clutch | Clutch release assembly
CHAPTER SEVEN: TRANSMISSION and GEARSHIFT MECHANISMS
Shift pedal/lever assembly | External shift mechanism | Transmission and internal shift mechanism
CHAPTER EIGHT: FUEL, EMISSION CONTROL and EXHAUST SYSTEMS
Carburetor operation | Carburetor service | Carburetor | Carburetor service | Carburetor adjustments | Fuel system cleanliness inspection | Throttle cable replacement | Choke cable replacement | Air filter | Fuel tank | Fuel shutoff valve and filter | Crankcase breather system (U.S. only) | Evaporative emission control system (California models only) | Vacuum switch valve | Air suction valve | Exhaust system
CHAPTER NINE: ELECTRICAL SYSTEM
Electrical connectors | Battery negative terminal | Charging system | Voltage regulator/rectifier | Alternator | Transistorized ignition system | Starter system | Electric starter | Starter relay | Lighting system | Switches | Electrical components | Junction box | Main fuse | Wiring diagrams
CHAPTER TEN: COOLING SYSTEM
Hoses and hose clamps | Cooling system inspection | Coolant reservoir | Radiator and radiator fan | Radiator fan | Thermostat | Water pump
CHAPTER ELEVEN: FRONT SUSPENSION and STEERING
Front wheel | Front hub | Wheels | Tires | Tire changing | Tire repairs | Handlebar | Steering head and stem | Steering head bearing races | Front fork
CHAPTER TWELVE: REAR SUSPENSION
Rear wheel | Rear hub | Rear wheel coupling and rear sprocket | Drive chain | Tire changing and tire repair | Shock absorber | Swing arm and shock linkage
CHAPTER THIRTEEN: BRAKES
Front disc brakes | Front brake pad replacement | Front brake caliper | Front master cylinder | Front brake hose replacement | Front brake disc | Bleeding the system | Rear drum brake | Rear brake pedal | Rear brake cable/rod assembly
CHAPTER FOURTEEN: FRAME
Seat | Frame side covers | Storage box | Tool box | Footpegs | Sidestand | Front fender | Rear fender | Frame
WIRING DIAGRAMS
The Kawasaki Vulcan manual by Clymer is the best reference book for repair and service information for your Vulcan 800 (VN800) motorcycle.
Publisher: Clymer Manuals — 2007
Author: Ed Scott
Binding: Paperback — 7 x 10 inches
Pages: 400 — Hundreds of b&w photos and illustrations
ISBN: 9781599691862
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