2009 Kawasaki Vulcan 1700 Voyager & Voyager ABS (VN1700) Service Manual (P/N 99924-1413-02)

This Kawasaki service manual, P/N 99924-1413-02, covers the 2009–2010 VULCAN 1700 VOYAGER, VULCAN 1700 VOYAGER ABS and VN1700 VOYAGER ABS. It distinguishes the VN1700A non-ABS models from the VN1700B models equipped with K-ACT ABS.

• Engine repair: Engine removal and installation, cylinder-head disassembly, camshaft timing, crankcase splitting, crankshaft inspection and transmission shaft service.

• Fuel injection and throttle control: DFI service-code retrieval, ECU terminal checks, fuel-pressure testing and Electronic Throttle Valve (ETV) diagnosis.

• Clutch and final drive: Hydraulic clutch service, clutch-pack inspection, pulley removal, drive-belt replacement and belt-deflection inspection and adjustment.

• Cooling and lubrication: Cooling-system pressure testing, thermostat inspection, water-pump mechanical-seal replacement and engine oil-pressure measurement.

• Brakes and chassis: Caliper and master-cylinder repair, K-ACT ABS fault tracing, brake-line bleeding, fork overhaul and steering-bearing replacement.

• Electrical and touring equipment: Charging, ignition and starter tests, electronic cruise-control switch inspection, audio-system troubleshooting and model-specific wiring diagrams.

Written primarily for trained mechanics in a properly equipped shop, the manual also supports owners performing basic maintenance and repair who already understand mechanics, tool use and workshop procedures.

DFI Diagnosis and Electronic Throttle Control

The DFI System Wiring Diagram, ECU pin assignments and sensor voltage and resistance tests support tracing circuit faults before replacing components. Separate diagnostic sections address throttle-position sensors, accelerator-position sensors, the ETV actuator and the system’s fail-safe modes.

Throttle-body limits: The factory-set sensors, ETV actuator and throttle linkage are not intended for internal adjustment. Disturbing these settings can cause poor performance and require throttle-body replacement. The ECU and throttle-body replacement procedures also explain the throttle-position learning requirement.

Engine, Clutch and Final-Drive Repair

Internal engine work: Cylinder and valve inspections, piston-ring wear checks and connecting-rod bearing-clearance measurements support internal repair. Hydraulic lash adjuster removal and air bleeding are covered; routine valve-clearance adjustment is unnecessary with the HLA system.

Clutch differences: The manual separates the clutch spring, holder and cam-damper arrangements used on VN1700A9F/B9F and VN1700AAF/BAF models. These distinctions help identify the correct assembly before parts are selected.

Drive-belt service: Deflection checks specify Kawasaki Tension Gauge 57001-1585. The handling precautions explain how sharp bending or twisting can damage the belt’s tensile cords, even before installation.

Cooling, Lubrication and Scheduled Maintenance

Factory inspection schedules cover fluid changes, filter replacement and routine chassis checks. The cooling chapter adds radiator-cap testing, water-pump seal work and the Coolant Flow Chart.

The Engine Oil Flow Chart accompanies oil-pump, oil-screen and pressure-relief-valve service. Component-specific torque tables cover the oil filter and drain bolts, while the wheel and final-drive sections provide rear-axle tightening data.

K-ACT ABS, Suspension and Steering

The Kawasaki Advanced Coactive-braking Technology sections include the K-ACT ABS Diagnosis Flow Chart and separate VN1700B9F and VN1700BAF wiring and pressure-sensor checks. Hydraulic-unit removal, installation and brake-line bleeding are documented; internal hydraulic-unit rebuilding is outside the prescribed repair scope.

Chassis service: Fork procedures distinguish VN1700A and VN1700B oil specifications. Rear air-shock adjustment, swingarm service and steering-stem bearing replacement are also covered. The troubleshooting guide addresses engine noise, overheating and handling complaints.

Cable, Wire, and Hose Routing views show brake plumbing and harness paths through the touring bodywork. Appropriate lifting equipment and secure motorcycle support are essential during wheel, fork and engine removal.

Electrical Systems and Touring Accessories

Electrical testing extends to the regulator/rectifier, starter motor, ignition coils and meter CAN communication. Separate main wiring diagrams identify the non-ABS, B9F and BAF configurations.

Touring-equipment coverage includes radio destination settings, audio accessory connections and cruise-control cancel-switch checks. Fairing, trunk and saddlebag removal procedures explain access to the surrounding components.

A Sample of Cooling, Ignition and Brake Specifications

These examples show a small selection of the manual’s service data. Cooling-system capacity is 2.4 L (2.5 US qt), including the radiator and engine with the reserve tank at its full level.

The ignition specifications list a 1.0–1.1 mm gap for the NGK ILZKAR7B11 spark plug. Front brake-pad inspection data distinguish the standard 4.0 mm lining thickness from the 1 mm service limit.

Searchable Text, Bookmarks and PDF Contents

Search and diagram detail: Main text supports PDF search, while some labels within wiring diagrams and illustrations are not searchable. Embedded bookmarks provide chapter and procedure navigation. Small wiring labels require zooming for clear reading.

One printable English PDF contains 794 pages: 773 chapter pages, six introductory pages, two cover/model-application pages, ten blank pages and three placeholder pages. All are already included in the total.