1996-2006 Kawasaki Vulcan 800 Classic & VN800 Classic Motorcycle Service Manual

Comprehensive service manual for Kawasaki Vulcan 800 Classic and VN800 Classic models, covering 1996-2006. Includes detailed procedures for engine, chassis, electrical, and fuel systems.

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Document Details

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Document Number / Seller:
26285 / Donna Reyes
File Size:
6.56 MB
File Type:
ZIP
Language:
English
Pages:
395
Printable:
Yes
Estimated Download Time:
0.13 Minutes
Delivery Format:
Digital (PDF) - Instant Access
Category:
Motorbike
Brand:
Kawasaki
Reviewed and Approved:
Dec 29, 2025
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Models Covered & Key Technical Specifications

Kawasaki Vulcan 800 Classic & VN800 Classic (9606)

Comprehensive service manual for Kawasaki Vulcan 800 Classic and VN800 Classic models, covering 1996-2006. Includes detailed procedures for engine, chassis, electrical, and fuel systems.

  • Certified Engine Specs: 805 cc displacement establishes the maximum engine displacement
  • General Performance Data: For optimal operation, 64 N·m torque yields the maximum power output
  • Defined Cooling System: The cooling system specifies the permanent type antifreeze
  • Key Chassis Specifications: The frame requires a tubular, double cradle for standard operation
  • Primary Drive Train Data: The primary reduction ratio corresponds to 2.184
  • Baseline Electrical Specs: The battery maintains 12 V 12 Ah Standards

Professional Workshop Service Manual & Technical Specifications

Kawasaki Vulcan 800 Classic & VN800 Classic Motorcycle Service Manual: 1996-2006 Technical-Guide

Engine-Type: V2-cylinder / Year-Coverage: 1996-2006 / Performance-Values: 40.5 kW @7000 rpm

Assessment-Element Parameters Framework
Engine Type 4-Stroke, SOHC, V2-cylinder Performance
Cooling System Liquid-cooled Efficiency
Displacement 805 cm³ (49.1 cu in.) Power
Compression Ratio 9.5: 1 Efficiency
Max Horsepower 40.5 kW (55 PS) @7000 r/min Performance
Max Torque 64 N·m (6.5 kgf·m, 47.0 ft·lb) @3300 r/min Torque
Carburetion System Carburetor, Keihin CVK36 Fuel Delivery
Ignition System Battery and coil (transistorized) Ignition
Transmission 5-speed, constant mesh, return shift Drivetrain
Front Tire Size 130/90-16 67H Roadability
Rear Tire Size 140/90-16 71H Roadability
Front Suspension Telescopic fork Ride Comfort
Rear Suspension Swingarm (uni-trak) Ride Comfort
Brake Type Front Single disc Braking
Brake Type Rear Drum Braking
Battery 12 V 12 Ah Electrical
Alternator Rated Output 23.5 A @8000 r/min, 14 V Electrical

Repair data is categorized into sections covering:

Introduction and Specifications

Engine Top End Procedures

Drivetrain and Transmission Service

Fuel System Maintenance

Cooling System Overhauls

Electrical System Diagnostics

This manual meticulously details every system, procedure, and specification essential for the maintenance and repair of your Kawasaki Vulcan 800 Classic and VN800 Classic motorcycles. It provides a logical sequence for disassembly and reassembly, ensuring accuracy and efficiency. The document covers the extensive range of maintenance procedures, from basic checks to complex overhauls. Systematically requiring proper care and attention, this guide leads you through each step with clear instructions. The manual documents torque specifications for critical components to ensure proper bolt stretch prevention and optimal performance. It also outlines maintenance schedules and diagnostic procedures for all major motorcycle systems.

FAQ

What is the **required** engine oil capacity for this Kawasaki model? keyboard_arrow_down

2.7 L (2.9 US qt) when the filter is not removed, 2.9 L (3.1 US qt) when the filter is removed, and 3.2 L (3.4 US qt) when the engine is completely dry is the required engine oil capacity.

Calculate the **specified** valve clearance for the inlet and exhaust valves. keyboard_arrow_down

0.10-0.15 mm (0.004-0.006 in.) is the specified inlet valve clearance, and 0.20-0.25 mm (0.008-0.010 in.) is the specified exhaust valve clearance.

What values are **essential** for the spark plug gap? keyboard_arrow_down

0.7-0.8 mm (0.028-0.031 in.) are the essential values for the spark plug gap.

Assess the **correct** brake fluid specification for this motorcycle. keyboard_arrow_down

DOT4 is the correct specification for the brake fluid in this motorcycle.

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Reviews (5)

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Rated 5 out of 5 stars
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This manual is incredibly detailed and has been a lifesaver for my maintenance needs. The download process was seamless, and I received the link almost instantly. Highly recommend!
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The manual covers everything! Plus, the download link arrived in my email right away. A must-have for anyone with a Vulcan 800. I’m very satisfied!
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This manual is thorough and easy to follow. I had a question and the support team was very helpful and quick to respond. Smooth experience overall!
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As a first-time bike owner, this manual made everything clear. The support team responded quickly to my questions, making the experience even better. Great purchase!