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1996-2002 Kawasaki Vulcan 800, VN 800 service manual Preview image 1
1996-2002 Kawasaki Vulcan 800, VN 800 service manual Preview image 2
1996-2002 Kawasaki Vulcan 800, VN 800 service manual Preview image 3
1996-2002 Kawasaki Vulcan 800, VN 800 service manual Preview image 4
1996-2002 Kawasaki Vulcan 800, VN 800 service manual Preview image 5
1996-2002 Kawasaki Vulcan 800, VN 800 service manual Preview image 6

1996-2002 Kawasaki Vulcan 800, VN 800 service manual

Models covered in this manual:

Vulcan 800, VN 800 / Kawasaki Motorcycle & Engine Company

  • 1996 VN800-B1
  • 1997 VN800-B2
  • 1998 VN800-B3
  • 1999 VN800-B4
  • 2000 VN800-B5
  • 2001 VN800-B6
  • 2002 VN800-B7
  • Supplement 2000-2001 Models
  • Supplement 2002-2003 Models
  • Supplement 2004 Models
  • Engine: 805 cc (49.1 cu in) liquid-cooled four valves per cylinder V-twin

File specifications

File size: 42.57 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 0.87 Minutes
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Product Information

Table of Contents

General Information

  1. General Information
    • Model Identification
    • Specifications
    • Torque Specifications
    • Special Tools

Fuel System

  1. Fuel System
    • Fuel Tank
    • Fuel Petcock
    • Carburetor Assembly
    • Air Cleaner

Cooling System

  1. Cooling System
    • Radiator and Cooling Fan
    • Coolant Replacement
    • Thermostat Inspection
    • Cooling System Troubleshooting

Engine Top End

  1. Engine Top End
    • Cylinder Head Removal
    • Valve Adjustment
    • Camshaft and Timing Chain
    • Piston and Cylinder Inspection

Clutch

  1. Clutch
    • Clutch Plate Replacement
    • Clutch Cable Adjustment
    • Clutch Mechanism Service
    • Troubleshooting Clutch Issues

Engine Lubrication System

  1. Engine Lubrication System
    • Oil Pump
    • Oil Filter Replacement
    • Oil Cooler
    • Engine Oil Specifications

Engine Removal/Installation

  1. Engine Removal/Installation
    • Engine Removal Procedure
    • Engine Installation Procedure
    • Engine Mounting and Alignment
    • Pre-Installation Checklist

Crankshaft/Transmission

  1. Crankshaft/Transmission
    • Crankshaft Service
    • Transmission Disassembly
    • Gear Inspection and Replacement
    • Shift Mechanism

Wheels/Tires

  1. Wheels/Tires
    • Wheel Removal and Installation
    • Tire Inspection and Replacement
    • Wheel Bearings
    • Tire Pressure and Wear

Final Drive

  1. Final Drive
    • Chain and Sprockets
    • Final Drive Inspection
    • Lubrication
    • Adjustment Procedures

Brakes

  1. Brakes
    • Brake Pad Replacement
    • Brake Fluid Replacement
    • Brake Line Inspection
    • Troubleshooting Brake Issues

Suspension

  1. Suspension
    • Front Fork Service
    • Rear Shock Absorber
    • Suspension Adjustment
    • Swingarm and Linkage

Steering

  1. Steering
    • Handlebar Adjustment
    • Steering Stem Bearings
    • Steering Inspection
    • Steering Damper

Frame

  1. Frame
    • Frame Inspection and Repair
    • Frame Alignment
    • Frame Mounting Points
    • Frame Maintenance

Electrical System

  1. Electrical System
    • Wiring Diagram
    • Battery Maintenance
    • Charging System
    • Lighting and Switches

Supplements

  1. Supplement-2000 to 2001 Models

    • Model-Specific Changes
    • Updated Specifications

  2. Supplement-2002 to 2003 Models

    • Model-Specific Changes
    • Updated Specifications

  3. Supplement-2004 Models

    • Model-Specific Changes
    • Updated Specifications

Appendix

  1. Appendix
    • Conversion Tables
    • Troubleshooting Guide
    • Service Data
    • Index

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