Clymer Kawasaki VN800 Vulcan 1995-2005 Motorcycle Repair Manual

Description

This Clymer Kawasaki VN800 Vulcan 1995-2005 Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for VN800 Vulcan (1995-2005) and Vulcan Classic (1995-2005) motorcycles.

1995 1996 1997 1998 1999
2000 2001 2002 2003 2004 2005

QUICK REFERENCE DATA

CHAPTER ONE, GENERAL INFORMATION
Manual organization, Notes, cautions and warnings, Safety first, Service hints, Washing the motorcycle, 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

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 inspection, Pre-ride inspection, Service intervals, Tires and wheels, Battery, New battery installation, Battery electrical cable connectors, Periodic lubrication, Periodic maintenance, Tune-up

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

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

CHAPTER SIX, CLUTCH
Clutch cable, Clutch cover, Clutch, Clutch release assembly

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

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 only), Vacuum switch valve, Air suction valve, Exhaust system

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

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

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

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

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

CHAPTER FOURTEEN, FRAME
Seat, Frame side covers, Storage box, Tool box, Footpegs, Sidestand, Front fender, Rear fender, Frame

INDEX

WIRING DIAGRAMS