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Kawasaki VN900 Classic Service Manual

Kawasaki VN900 Classic
588 pages
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VULCAN900 CLASSIC
VULCAN900 CLASSIC LT
VN900 CLASSIC
Motorcycle
Service Manual

Table of Contents

Other manuals for Kawasaki VN900 Classic

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Kawasaki VN900 Classic Specifications

General IconGeneral
BrandKawasaki
ModelVN900 Classic
CategoryMotorcycle Accessories
LanguageEnglish

Summary

General Information

Before Servicing

Covers essential precautions before starting inspection, disassembly, or reassembly.

General Specifications

Lists key technical data for the motorcycle, including dimensions and performance.

Model Identification

Provides visual guides for identifying specific motorcycle models and their key numbers.

Periodic Maintenance

Periodic Maintenance Chart

Outlines scheduled maintenance tasks based on time or odometer readings.

Torque and Locking Agent

Lists tightening torques and recommended locking agents for various fasteners.

Specifications

Provides detailed standard and service limit values for various motorcycle components.

Special Tools

Lists specialized tools required for periodic maintenance procedures.

Periodic Maintenance Procedures

Details various maintenance procedures for different motorcycle systems.

Fuel System (DFI)

Exploded View

Provides visual part breakdown of the Fuel System (DFI).

DFI Parts Location

Illustrates the location of various DFI system components on the motorcycle.

Specifications

Lists key technical data and standard values for DFI system components.

DFI Servicing Precautions

Outlines critical safety and procedural advice for servicing the DFI system.

Troubleshooting the DFI System

Provides guidance and flowcharts for diagnosing DFI system issues.

Engine Top End

Exploded View

Provides visual part breakdown of the Engine Top End.

Specifications

Lists key technical data and standard/service limit values for engine top end components.

Special Tools

Lists specialized tools required for engine top end service.

Clean Air System

Details removal, installation, and inspection of air suction and switching valves.

Cylinder Head Cover

Covers removal and installation of the cylinder head cover.

Camshaft, Camshaft Chain

Covers camshaft removal, installation, and wear inspection.

Valves

Details valve clearance inspection, adjustment, removal, and installation.

Cylinders, Pistons

Covers cylinder removal, piston removal, and cylinder/piston installation.

Muffler

Details the steps for removing and installing the muffler assembly.

Clutch

Exploded View

Provides visual part breakdown of the Clutch system.

Specifications

Lists key technical data and standard/service limit values for clutch components.

Special Tool

Lists the specialized tool required for clutch service.

Clutch Lever and Cable

Covers inspection and adjustment of clutch lever free play, and cable removal/installation.

Right Engine Cover

Details removal and installation of the right engine cover.

Clutch

Details clutch removal and installation, including friction plates and hub nut.

Clutch Plate, Wear, Damage Inspection

Covers visual inspection and thickness measurement of clutch plates.

Engine Lubrication System

Exploded View

Provides visual part breakdown of the Engine Lubrication System.

Specifications

Lists key technical data for engine oil and pressure measurements.

Special Tools and Sealant

Lists specialized tools and sealants required for engine lubrication system service.

Engine Oil and Oil Filter

Covers oil level inspection, oil change, filter change, and oil screen cleaning.

Oil Pressure Relief Valve

Details removal, installation, and inspection of the oil pressure relief valve.

Oil Pump, Oil Pump Drive Chain

Covers removal, installation, and drive chain guide installation for the oil pump.

Oil Pressure Measurement

Details how to measure engine oil pressure using a gauge.

Oil Pressure Switch

Covers removal, installation, and inspection of the oil pressure switch.

Oil Pipe and Oil Hose

Details removal and installation of oil pipes and hoses on the crankcase.

Engine Removal/Installation

Exploded View

Provides visual part breakdown for engine removal/installation.

Special Tool

Lists the specialized tool required for engine removal/installation.

Engine Removal

Details the procedures for removing the engine from the frame.

Engine Installation

Covers installing the engine back into the frame, including tightening and adjustments.

Crankshaft/Transmission

Exploded View

Provides visual part breakdown of the Crankshaft/Transmission.

Specifications

Lists key technical data and standard/service limit values for crankshaft/transmission.

Special Tools and Sealants

Lists specialized tools and sealants required for crankshaft/transmission service.

Crankcase Splitting

Details the procedure for splitting the crankcase halves.

Crankshaft/Connecting Rods

Covers crankshaft removal/installation and connecting rod procedures.

Balancer, Starter Motor Clutch

Details removal and installation of the left and right balancers and starter motor clutch.

Torque Limiter

Covers removal and inspection of the torque limiter.

Primary Gear

Details removal and installation of the primary gear.

Transmission

Covers shift pedal, external shift mechanism, and transmission shaft procedures.

Wheels/Tires

Exploded View

Provides visual part breakdown of the Wheels/Tires.

Specifications

Lists key technical data and standard/service limit values for wheels and tires.

Special Tools

Lists specialized tools required for wheel and tire service.

Wheels (Rims)

Covers front and rear wheel removal and installation.

Tires

Details tire removal, installation, and tread wear inspection.

Hub Bearing

Covers hub bearing removal, installation, inspection, and lubrication.

Final Drive

Exploded View

Provides visual part breakdown of the Final Drive.

Specifications

Lists key technical data for the drive belt and pulleys.

Special Tools

Lists specialized tools required for final drive service.

Drive Belt

Covers belt handling precautions, wear, deflection inspection, and removal/installation.

Pulley and Coupling

Details engine and rear pulley cover removal/installation, and pulley removal/installation.

Coupling Bearing Removal

Covers removal of coupling bearings, seals, and related parts.

Coupling Bearing Installation

Details the installation of new coupling bearings and seals.

Coupling Bearing Inspection

Covers inspection of coupling bearings and sleeves for wear.

Rubber Damper Inspection

Details inspection and replacement of rubber dampers in the rear wheel coupling.

Belt Adjuster

Covers removal and installation of the belt adjuster components.

Brakes

Exploded View

Provides visual part breakdown of the Brakes system.

Specifications

Lists key technical data and standard/service limit values for brake components.

Special Tool

Lists the specialized tool required for brake service.

Brake Lever, Brake Pedal

Covers position adjustment for brake lever and pedal, and their removal/installation.

Calipers

Details front and rear caliper removal, installation, disassembly, and assembly.

Brake Pads

Covers front and rear brake pad removal and installation, and wear inspection.

Master Cylinder

Details front and rear master cylinder removal, installation, disassembly, and inspection.

Brake Discs

Covers brake disc removal, installation, wear, and warp inspection.

Brake Fluid

Details brake fluid level inspection, change, and brake line bleeding.

Suspension

Exploded View

Provides visual part breakdown of the Suspension system.

Specifications

Lists key technical data and standard/service limit values for suspension components.

Special Tools

Lists specialized tools required for suspension service.

Front Fork

Covers front fork removal, installation, oil change, disassembly, and assembly.

Rear Shock Absorber

Details spring preload adjustment, removal, installation, and inspection.

Swingarm

Covers swingarm removal, installation, bearing removal/installation, and inspection.

Tie-Rod, Rocker Arm

Details removal and installation of tie-rods, rocker arms, and their bearings.

Steering

Exploded View

Provides visual part breakdown of the Steering system.

Special Tools

Lists specialized tools required for steering service.

Handlebar

Covers handlebar removal and installation.

Steering

Refers to Periodic Maintenance chapter for steering inspection and adjustment.

Steering Stem

Details steering stem removal, installation, and warp inspection.

Steering Stem Bearing

Covers steering stem bearing removal, installation, and lubrication.

Frame

Exploded View

Provides visual part breakdown of the Frame.

Special Tool

Lists the specialized tool required for frame service.

Seats

Covers seat removal and installation procedures.

Side Covers

Details removal and installation of left and right side covers.

Fenders

Covers front and rear fender removal and installation.

Battery Case

Details removal of the battery case and related electrical components.

Tool Box

Covers the removal of the tool box.

Footboard

Details footboard removal/installation and disassembly/assembly.

Sidestand

Covers sidestand removal, installation, and switch inspection.

Windshield (VN900D Models)

Details windshield height adjustment, removal, and assembly/installation.

Saddlebags (VN900D Models)

Covers saddlebag removal and installation.

Rear View Mirrors

Details rear view mirror removal and installation for different models.

Downtube

Covers downtube removal and installation, including related components.

Back Rest (VN900D Models)

Details back rest removal and installation.

Frame

Covers frame inspection for damage like cracks or warping.

Electrical System

Exploded View

Provides visual part breakdown of the Electrical System.

Electrical Parts Location

Illustrates the location of various electrical system components.

Wiring Diagram

Provides wiring diagrams for different models, crucial for electrical troubleshooting.

Specifications

Lists key technical data for electrical system components.

Special Tools and Sealant

Lists specialized tools and sealants required for electrical system service.

Precautions

Outlines critical safety and procedural advice for servicing electrical systems.

Electrical Wiring

Covers inspection of wiring for damage and continuity.

Battery

Details battery removal, installation, activation, and charging.

Charging System

Covers alternator cover, stator coil, and rotor removal/installation/inspection.

Ignition System

Details ignition system troubleshooting, coil removal/installation/inspection, and spark plug inspection.

Electric Starter System

Covers starter motor removal, installation, disassembly, and assembly.

Lighting System

Details headlight beam adjustment, bulb replacement, and removal/installation.

Meter Unit

Covers meter unit removal, installation, disassembly, and inspection of displays and lights.

Appendix

Cable, Wire and Hose Routing

Provides diagrams and instructions for routing cables, wires, and hoses.

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