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  Kawasaki VN800 Vulcan, Vulcan Classic Repair Manual 1995-2005
  Kawasaki VN800 Vulcan, Vulcan Classic Repair Manual 1995-2005
 
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Product Code: CL-M354-3

 
 
This repair & service manual covers Kawasaki Vulcan 800 VN800A, 1995 to 2005 and Vulcan Classic VN800B, 1996 to 2005. Note: This manual does NOT cover the VN800C/E Drifter models

Table of Contents

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

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.
 PRODUCT DETAILS:

  • Publisher: Clymer Manuals ó 2007
  • Author: Ed Scott
  • Binding: Paperback ó 7 x 10 inches
  • Pages: 400 ó Hundreds of b&w photos and illustrations
  • ISBN:1599691868

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