Oil Baffle EO: Apply engine oil. G: Apply grease. Torque - Engine Ground Terminal Bolt: 7. LG: Apply liquid gasket Kawasaki Bond: The left balancer gear bolt has right-hand threads. If the limiter has wear, discoloration, or other damage, replace it as a set. Crankpin Diameter Standard: If the measurement exceeds the service limit, replace the crankshaft. Be sure to install the washer [D] onto the shift shaft. Do not confuse them.
Shift Fork No. Using the circlip pliers special tool , remove the circlips, and disassemble the transmission shaft. Special Tool - Outside Circlip Pliers: The 4th gear [A] on the output shaft has three steel balls for the positive neutral finder mechanism.
A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear under load. Circlip Needle Bearing Output Shaft Thrust Washer Removal may damage them.
Replace it if the lips are misshapen, discolored indicating that the rubber has deteriorated , hardened or otherwise damaged. Radial TIR 0. Wheel balance 10 g 0. Page Balance Weight Removal — 30 1. An imbalance of less than 10 grams 0.
This helps the balance weight slip onto the rim flange. Page Tire Repair Also, permanent internal repairs have the advantage of permitting a thorough examination for secondary damage not visible from external inspection of the tire.
For these reasons, Kawasaki does not recommend temporary exter- nal repair. Only appropriate permanent internal repairs are recommended. Repair methods may vary slightly from make to make. Final Gear Case Removal If the final gear case is to be disassembled, drain the final gear case oil.
The shim s comes off with the assy. Pinion Gear Nut Studs 2. Washer Pinion Gear Shim s 3. Shim s for Preload O-ring 4. Pinion Gear Joint Oil Seal 5. O-ring Tapered Roller Bearings 6. Bearing preload is defined as the force or torque which is needed to start the gear shaft turning. Washer 5. Shim s 6. If it does not work smoothly, the needle bearings of the universal joint are damaged. Replace the propeller shaft assy with a new one. Bearing Housing 3. Spacer 5. Tapered Roller Bearing 2.
Tapered Roller Bearing 4. If there is any doubt as to the condition of the bearing, replace it. Either side of the fluid seal may face outboard.
Take care that neither the cylinder nor the piston skirt gets scratched. The rear caliper pad removal s the same as for the front cali per. If a master cylinder or piston shows any damage, replace them. Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time.
R: Replacement Parts G: Apply grease. WL: Apply a soap and water solution or rubber lubricant. If the spring of either fork leg is shorter than the service limit, it must be replaced.
The numbers on the adjuster show the sett ng posit ion. Instead of measuring, inspect the bearing in the shock absorber for abrasion, color change, or other damage. If not, the steering stem bearings may be damaged. Tool box 3.
Battery case 4. Front fender 5. Rear fender 6. Front seat 7. Rear seat G: Apply grease. If there is any damage to the frame, replace it. If the frame is bent, dented, cracked, or warped, replace it. Si: Apply silicone grease.
Page 9. DFI main relay Turn signal control relay Starter Relay Horn Electronic control unit Junction Box Vehicle-down sensor Atmospheric pressure sensor This will burn out the diodes on the electrical parts. If any wiring is poor, replace the damaged wiring. If the connector is corroded or dirty, clean it carefully. Never reverse the connections of the battery, this could damage the ECU.
Now the electrolyte should start to flow into the battery. Therefore, replace the sealed battery only on a motorcycle which was originally equipped with the sealed battery. If quick charge is done unavoidably, do standard charge later on.
Ignition Switch 6. Battery 2. Alternator 2 inside stator 7. Joint Connector 3. Main Fuse 30 A 4. Alternator 1 outside stator 9. Starter Relay 5. Do not touch the spark plugs, ignition coils, or spark plug high-tension cables while the engine is running, or you could receive a severe electrical shock. Ignition Switch 8. Crankshaft Sensor 2 Engine Stop Switch rear cylinder Junction Box 3.
Starter Button 9. DFI Fuse 15 A Ignition Fuse 10 A 4. Spark Plugs Torque - Starter Motor Assembly Bolts: 4. If any is worn down to the service limit, replace the carbon brush holder assy [B] and the terminal bolt assy [C]. Ignition Fuse 10 A Starter Motor 2. Engine Stop Switch 7. Starter Lockout Switch Starter Relay 3. Starter Button 8.
Side Stand Switch The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on when the engine starts running and stays on even if the engine stalls. Main Fuse 30A 1. Headlight 2. Alternator 9. License Plate Light Battery 3. Headlight Relay Running Position Lights 4. Headlight Fuse 10 A But, motorcycles turn with a bank additionally, and so have a smaller steer angle. This makes difficult to adopt an automobile type turn signal canceling system because of inaccurate operation in motorcycles.
Ignition Switch 9. Front Right Turn Signal Light 2. Rear Left Turn Signal Light 3. Rear Right Turn Signal Light 4. The fan may start even if the ignition switch is off. Damper [C] Outside Diameter: 16 mm 0. Cover [I] Such a shock to the meter unit can damage it. Place the meter facing up. If the indicator light does not go on, inspect the bulb. Meter Unit Fuel Level Sensor 2. Fuel Reserve Switch 3. Speedometer Turn Signal Control Relay 4. Fuel Meter Frame Ground 5. Illuminator LED Water Temperature Switch 6.
The relays and diodes can not be removed. Accessory Fuse 10 A D. Horn Fuse 10 A I. Starter Diode B. Fan Fuse 10 A E. Ignition Fuse 10 A J. Fuel Tank 2. Welcome, Kawasaki owners. Access the information and tools you need to get the most out of your vehicle. Searching for models or older? Please contact Customer Support for assistance. No accessories found.
No two are alike. Each Kawasaki product line has a distinct VIN location. The exact location for these numbers in your particular model is illustrated in your owner's manual near the front of the book. By implementing instrument on board, Kawasaki has been succeeded in giving this cruiser a perfect combination of tank decoration. Further, this bike also looks interesting with the two-pieces seats and pulled-back handlebars. To support the high performance it has, this bike is completed with such a sophisticated engine.
And as its name, the engine has cc o displacement. What a big displacement for a motorcycle product in its class. With this engine system, this bike is able to produce huge power that will be transmitted to its 5-level of speed transmission. As stated before, it is very important for users to have the Kawasaki Vulcan VN Classic Manual, especially for the new users.
From this manual, they can understand about what are needed in caring and operating their Kawasaki Vulcan VN Classic product. It is because in Kawasaki Vulcan VN Classic Manual, you will find a lot of information such as operation, function, spare parts, and others related to this product. Therefore, understanding the basic principle of this rugged cruiser product will be easy.
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