• MOTORCYCLE SERVICE MANUAL

MOTORCYCLE SERVICE MANUAL

MOTORCYCLE SERVICE MANUAL

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MODELS COVERED:

VN800A Vulcan 800 (1995-2005)
VN800B Vulcan 800 Classic (1995-2005)

This manual does not cover VN800C/E Drifter models.

This Kawasaki Vulcan Manual is 408 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Washing the bike / Special tips / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Gasket remover / Threadlocking compound / Expendable supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Special tools / Fabricating tools / Mechanic’s tips / Ball bearing replacement / Seals / Riding safety / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Starting the engine / Emergency troubleshooting / Engine starting troubleshooting / Engine performance / Engine noises / Engine lubrication / Clutch / Gearshift linkage / Transmission / Electrical troubleshooting / Test equipment / Basic test procedures / Electrical problems / Charging system troubleshooting / Ignition system troubleshooting / Starter system troubleshooting / Carburetor troubleshooting / Excessive vibration / Front suspension and steering / Brake problems

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Pre-checks / Service intervals / Tires and wheels / Battery / New battery installation / Battery electrical cable connectors / Periodic lubrication / Engine oil and filter change / Engine oil pressure test / Fork oil change / Periodic maintenance / Drive chain cleaning and lubrication / Drive chain adjustment / Throttle adjustment / Air filter replacement / Coolant change / Tune-up / Valve clearance adjustment / Compression test / Spark plugs / Ignition timing / Carburetor idle mixture / Specifications

CHAPTER FOUR / ENGINE UPPER END
Engine principles / Servicing engine in frame / Cylinder head cover / Camshaft / Rocker arms/rocker shaft / Cam chain and chain guides / Cylinder head / Cylinder head inspection / Cam chain tensioner body inspection / Cylinder block / Valves and valve components / Pistons and piston rings / Break-in / Specifications Specs

CHAPTER FIVE / ENGINE LOWER END
Engine / Oil pump / Primary drive gear / Balancer assembly and starter gears / Crankcase / Crankshaft and connecting rods / Break-in / Specifications Specs

CHAPTER SIX / CLUTCH
Clutch cable / Clutch cover / Clutch / Clutch release assembly / Specifications Specs

CHAPTER SEVEN / TRANSMISSION AND GEARSHIFT MECHANISMS
Shift pedal/lever assembly / External shift mechanism / Transmission and internal shift mechanism / Specifications Specs

CHAPTER EIGHT / FUEL / EMISSION CONTROL AND EXHAUST SYSTEMS
Carburetor operation / Carburetor service / Carburetor / Carburetor service / Carburetor adjustments / Fuel system cleanliness inspection / Throttle cable replacement / Choke cable replacement / Air filter / Fuel tank / Fuel shutoff valve and filter / Crankcase breather system (U.S. only) / Evaporative emission control system (California models only) / Vacuum switch valve / Air suction valve / Exhaust system / Specifications Specs

CHAPTER NINE / ELECTRICAL SYSTEM
Electrical connectors / Battery negative terminal / Charging system / Voltage regulator/rectifier / Alternator / Transistorized ignition system / Starter system / Electric starter / Starter relay / Lighting system / Switches / Electrical components / Junction box / Main fuse / Wiring diagrams / Specifications Specs

CHAPTER TEN / COOLING SYSTEM
Hoses and hose clamps / Cooling system inspection / Coolant reservoir / Radiator and radiator fan / Radiator fan / Thermostat / Water pump / Specifications Specs

CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Wheels / Tires / Tire changing / Tire repairs / Handlebar / Steering head and stem / Steering head bearing races / Front fork / Specifications Specs

CHAPTER TWELVE / REAR SUSPENSION
Rear wheel / Rear hub / Rear wheel coupling and rear sprocket / Drive chain / Tire changing and tire repair / Shock absorber / Swing arm and shock linkage / Specifications Specs

CHAPTER THIRTEEN / BRAKES
Front disc brakes / Front brake pad replacement / Front brake caliper / Front master cylinder / Front brake hose replacement / Front brake disc / Bleeding the system / Rear drum brake / Rear brake pedal / Rear brake cable/rod assembly / Specifications Specs

CHAPTER FOURTEEN / FRAME
Seat / Frame side covers / Storage box / Tool box / Footpegs / Sidestand / Front fender / Rear fender / Frame / Specifications Specs

INDEX

WIRING DIAGRAMS
 

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MOTORCYCLE SERVICE MANUAL

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Product Specifications

General Information

Brandclymer
LabelKAW VLCN 800 AMP; CLASSIC 95-05
Universemoto
Categorymanuel_d_entretien
Supplier Part #CM3543
ITL ID252-M3543

Dimensions & Physical

Weight 1.587 lbs
Length10.25
Width7
Thickness1

Vehicle Fitment

Total Applications15
Applications KAWASAKI VN800-A VULCAN CUSTOM 1995KAWASAKI VN800-A VULCAN CUSTOM 1996KAWASAKI VN800-A VULCAN CUSTOM 1997KAWASAKI VN800-A VULCAN CUSTOM 1998KAWASAKI VN800-A VULCAN CUSTOM 1999KAWASAKI VN800-B VULCAN CLASSIC 1996KAWASAKI VN800-B VULCAN CLASSIC 1997KAWASAKI VN800-B VULCAN CLASSIC 1998KAWASAKI VN800-B VULCAN CLASSIC 1999KAWASAKI VN800-B VULCAN CLASSIC 2000KAWASAKI VN800-B VULCAN CLASSIC 2001KAWASAKI VN800-B VULCAN CLASSIC 2002KAWASAKI VN800-B VULCAN CLASSIC 2003KAWASAKI VN800-B VULCAN CLASSIC 2004KAWASAKI VN800-B VULCAN CLASSIC 2005
Makes KAWASAKI
Models VN800-A VULCAN CUSTOMVN800-B VULCAN CLASSIC
Years 19951996199719981999200020012002200320042005

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Highlight 1

Built for everyday use, the product features carefully chosen components that balance durability with visual appeal.

Highlight 2

Featuring a streamlined and compact design, the product is crafted to fit seamlessly into a variety of spaces and lifestyles.

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We offer a hassle-free returns policy to ensure your complete satisfaction. If you're not happy, simply return it within 30 days for a full refund.

Does it come with a warranty?

most items in store come with a manufacture defect warranty to give you peace of mind. we always strive to keep our customers happy with any issues on fitment or quality.

What happens if what i ordered does not fit?

If what you ordered does not fit, we will do a quick check for fitment via pictures of the item and your machine to verify. if the fitment widget was wrong-return cost is on us and a refund or instore credit will apply. Any other return is subject to a re-stocking fee and customer pays for return freight.

How fast is shipping?

most products leave same day if orderd before 11am. or next day if after that. delivery is anywhere from 2-7 days depending location in canada.

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