1995-2009 Kawasaki Vulcan 800 VN800 Motorcycle Service Manual

Wiring diagrams, specifications, and repair sequences for your Kawasaki Vulcan 800 / VN800 models (1995-2009). Includes detailed procedures and part numbers for complete servicing. Ref: 99969-1019

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Document Details

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Document Number / Seller:
31302 / William Taylor
File Size:
42.57 MB
File Type:
PDF
Language:
English
Pages:
405
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Dec 28, 2025

Models Covered & Key Technical Specifications

Kawasaki Vulcan 800 VN800 (99969-1019) Manual: Kawasaki Vulcan 800 VN800 - Motorcycle Service Manual & Repair Guide (1995-2009)

Engine-Type Resource Industrial | Application-Range Documentation Compendium. // Documentation-Type Catalog Professional.

  • Calibrated Moment Values: For optimal operation, 11 N-m (1.1 kg-m, 95 in-lb) is established at the lower bolt margin.
  • System Volume: For optimal cooling, 340 mL dictates the required capacity per side Protocol.
  • Critical Alignment Specs: The formatter board requires 2.3 kg-m (23 N-m, 16.5 ft-lb) for standard assembly Architecture.
  • Critical Assembly Torques: The rear wheel nut requires 98 N-m (10.0 kg-m, 72 ft-lb) for proper mounting Norms.
  • Universal Linear Velocity: Maximum throughput reaches 20 N-m (2.0 kg-m, 14.5 ft-lb) Bounds.
  • Core Assembly Torques: For optimal performance, 12 N-m (1.2 kg-m, 104 in-lb) is set to the shaft Topology.

Professional Workshop Service Manual & Technical Specifications

Kawasaki Vulcan 800 VN800 (99969-1019) Manual: Kawasaki Vulcan 800 VN800 - Motorcycle Service Manual & Repair Guide (1995-2009)

Engine-Type: VN800-A1, A2, A3, A4, A5 // Application-Range: 1995-2009 // Documentation-Type: Motorcycle

Identifier Operational-Logic Validation-Data
General Information Routine Checks Manual Reference
Engine Top End Component Assembly Specification Data
Fuel System Carburetor Service Diagram Analysis
Cooling System Coolant Maintenance Temperature Specs
Brakes Caliper Repair Fluid Levels

Diagnostic procedures address the complete service and repair of the Kawasaki Vulcan 800 and VN800 motorcycle models. This manual provides extensive technical information.

Wiring diagrams are provided for all electrical systems, ensuring clear understanding of the motorcycle's circuitry.

Fuel system procedures are documented for carburetor maintenance, including cleaning and adjustment sequences.

Adjustment procedures are detailed for critical components like the clutch and brake systems, ensuring optimal performance.

Timing procedures are documented for engine components to ensure correct synchronization and operation.

Technical notes are provided for specific model variations and special tools required for certain tasks.

This manual details torque specifications for various components to ensure proper assembly and prevent corrosion joint prevention.

FAQ

What values are **calibrated** for the system architecture? keyboard_arrow_down

11 N-m (1.1 kg-m, 95 in-lb) is the standard torque for the lower engine mounting bolts.

Assess the **applicable** tool requirements for disassembly. keyboard_arrow_down

57001-1057 (Fork Cylinder Holder Handle) and 57001-1058 (Oil Seal & Bearing Remover) are required for front fork seal replacement.

What components have **exact** electrical values listed? keyboard_arrow_down

The alternator output is rated at 23.5 A/14 V @ 5,000 r/min (rpm).

Confirm the **specific** calibration settings for optimal performance. keyboard_arrow_down

355 - 410 kPa (3.6 - 4.2 kg/cm², 51 - 60 psi) @4,000 r/min (rpm), oil temp. 100°C (212°F) is the standard oil pressure specification.

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The manual covers everything you need for maintenance. I had a quick question and the support team responded within hours. Fantastic service!
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This manual is incredibly detailed and easy to follow. The download process was seamless and I received my link promptly. Highly recommend!
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The manual is comprehensive and user-friendly. I appreciated the prompt email with the download link. Great customer support!