Kawasaki 2011–2017 Vulcan 1700 Vaquero / VN1700 Voyager Custom ABS Service Manual (P/N 99924-1444-02)

Kawasaki’s factory service manual for the Vulcan 1700 Vaquero and VN1700 Voyager Custom ABS covers 2011 VN1700JB and VN1700KB and 2012 VN1700JC and VN1700KC. This is the 2nd Edition (0), dated June 15, 2011 (P/N 99924-1444-02).

Searchable Service Text and Wiring Diagrams

Search, bookmarks, and diagrams: Searchable service text, embedded chapter and procedure bookmarks, and a clickable Quick Reference Guide. Labels inside the wiring drawings are part of the images. Zoom in to read the smallest connector labels and wire color codes.

The ZIP contains one printable PDF with 735 pages. The total includes 720 numbered pages, including the 52-page appendix, plus seven front-matter pages, seven blank pages, and the model-application back cover.

DFI Diagnostics, Engine Work, and K-ACT ABS

Across 17 chapters, these selected workshop topics sit alongside procedures such as thermostat testing and sidestand switch checks.

• Scheduled maintenance: Inspection and replacement procedures for filters, fluids, spark plugs, coolant hoses, and brake and clutch hydraulic parts.

• Digital fuel injection: DFI self-diagnosis, service-code reading, ECU and electronic throttle-valve circuit checks, fuel pressure and flow tests, and throttle-body removal and assembly.

• Engine and transmission: Engine removal, rocker-case and hydraulic lash-adjuster service, cam-chain timing, Kawasaki Automatic Compression Release (KACR) inspection, cylinder-head and piston work, crankcase separation, and six-speed gearbox overhaul.

• Brake hydraulics: Conventional VN1700J brakes and VN1700K K-ACT ABS, with bleeding procedures, ABS fault isolation, and wheel rotation sensor service.

• Chassis and belt drive: Wheel and tire service, front-fork overhaul, air-type rear-shock adjustment, swingarm and steering-stem service, and final-drive belt inspection and replacement.

• Electrical systems: Separate VN1700J and VN1700K wiring diagrams, charging and starting tests, meter and CAN checks, cruise-control switch tests, and audio troubleshooting.

The manual is written for trained mechanics in equipped workshops, including independent repair shops. Owners with mechanical experience can also use it for basic maintenance and repairs.

Fuel Injection and Market-Specific Equipment

The DFI Diagnosis Flow Chart and symptom guide help narrow a drivability complaint to a circuit or component. Tests cover accelerator and throttle position, intake pressure, air and coolant temperature, the vehicle-down sensor, and oxygen sensors on equipped models. The chapter also covers fuel pump and injector diagnosis, ignition coils and relays, air-cleaner service, and California evaporative-emissions equipment.

The DFI warning and active code clear from the display after repair. The ECU retains its stored fault history. The ECU identification table maps part numbers to the applicable market configurations. Other procedures distinguish European mirror work, city lights on models outside the US and Canada, and radio destination settings.

Engine, Clutch, and Belt Service

The bottom-end procedures cover crankshaft and connecting-rod inspection, balancer timing, starter-clutch service, and torque-limiter inspection. The hydraulic clutch chapter includes master- and slave-cylinder disassembly and assembly. The cooling and lubrication chapters cover the water pump and mechanical seal, oil pump and relief valve, oil-pressure testing, and the Engine Oil Flow Chart.

Final-drive procedures cover rear-wheel alignment and pulley removal. The belt-handling notes explain how tight bends and twisting can damage the tensile cords. Frame procedures cover fairings, saddlebags, footboards, and frame inspection.

K-ACT ABS Diagnostics and Repair Limits

The K-ACT ABS System Wiring Diagram and Diagnosis Flow Chart work with terminal assignments, the service-code table, and the ABS code-clearing procedure. The tests cover indicator and relay faults, solenoids, the front combine valve, wheel rotation sensors and rotors, and pressure-sensor circuits.

The factory-set ABS hydraulic unit is handled as a complete replacement assembly. The manual covers its removal and installation and specifies brake-line routing, leak checks, and bleeding after the system has been opened.

Wiring, Assembly Data, and Factory Tools

The model-specific diagrams identify the applicable harness, while the DFI System Wiring Diagram and appendix routing drawings help trace circuits and locate wires, cables, and hoses. The electrical chapter also covers ignition, lighting, automatic turn-signal canceling, speakers, the antenna, and accessory connections.

Exploded views, component torque tables, locking-agent callouts, wear limits, fluid capacities, and electrical test values accompany the procedures. Factory tools include the Hand Tester 57001-1394, Fuel Pressure Gauge Adapter 57001-1593, Valve Spring Compressor Assembly 57001-241, Pulley Holder 57001-1572, and Front Fork Oil Seal Driver 57001-1219.

Fuel Delivery and Belt Specifications

With a fully charged battery, the DFI procedures specify 294 kPa (43 psi) fuel pressure at idle and a separate pump delivery minimum of 29 mL (0.98 US fl oz) in 3 seconds.

The standard drive-belt deflection is 3.0–4.5 mm (0.12–0.18 in.) under a 45 N (10 lbf) load. The manual specifies 3.0 mm (0.12 in.) under the same load for a new belt or after engine remounting.