Kawasaki VN800 Vulcan, Vulcan Classic 1995 - 2005

Clymer Owners Service & Repair Manual

1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005

by Ed Scott

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Kawasaki VN800 Vulcan, Vulcan Classic 1995 - 2005 - Front Cover

Front Cover

Front Cover

description

Kawasaki VN800 Vulcan, Vulcan Classic 1995 - 2005 Clymer Owners Service & Repair Manual covers the following models:
● Kawasaki Vulcan 800 VN800A 1995 - 2005
● Kawasaki Vulcan Classic VN800B 1996 - 2005

Note: This manual DOES NOT cover VN800C/E Drifter models.

Contents:
Quick Reference Data

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 / MechanicĀfs Tips / Ball Bearing Replacement / Seals / Riding Safety / Storage / Specifications

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

Lubrication, Maintenance And Tune-Up
Routine Checks / Pre-Checks / Service Intervals / Tyres 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

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

Engine Lower End
Engine / Oil Pump / Primary Drive Gear / Balancer Assembly And Starter Gears / Crankcase / Crankshaft And Connecting Rods / Break-In / Specifications Specs

Clutch
Clutch Cable / Clutch Cover / Clutch / Clutch Release Assembly / Specifications Specs

Transmission And Gearshift Mechanisms
Shift Pedal/Lever Assembly / External Shift Mechanism / Transmission And Internal Shift Mechanism / Specifications Specs

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

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

Cooling System
Hoses And Hose Clamps / Cooling System Inspection / Coolant Reservoir / Radiator And Radiator Fan / Radiator Fan / Thermostat / Water Pump / Specifications Specs

Front Suspension And Steering
Front Wheel / Front Hub / Wheels / Tyres / Tyre Changing / Tyre Repairs / Handlebar / Steering Head And Stem / Steering Head Bearing Races / Front Fork / Specifications Specs

Rear Suspension
Rear Wheel / Rear Hub / Rear Wheel Coupling And Rear Sprocket / Drive Chain / Tyre Changing And Tyre Repair / Shock Absorber / Swing Arm And Shock Linkage / Specifications Specs

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

Frame
Seat / Frame Side Covers / Storage Box / Tool Box / Footpegs / Sidestand / Front Fender / Rear Fender / Frame / Specifications Specs

Wiring Diagrams

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 1599691868 (1-599-69186-8)
  • ISBN-13: 9781599691862 (978-1-599-69186-2)
  • Format: Softcover, 400 pages
  • Date Published: 03-2008

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