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Kawasaki VULCAN S ABS User Manual

Kawasaki VULCAN S ABS
695 pages
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VULCAN S
VULCAN S ABS

Table of Contents

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Kawasaki VULCAN S ABS Specifications

General IconGeneral
Displacement649cc
Bore x Stroke83.0 x 60.0 mm
Compression Ratio10.8:1
IgnitionDigital
Transmission6-speed, return shift
Final DriveSealed chain
Front Suspension41mm telescopic fork
Front Tire120/70x18
Rear Tire160/60x17
Seat Height705 mm
Ground Clearance130 mm
Engine Type4-stroke, Parallel Twin
Frame TypeHigh-Tensile Steel Diamond
Rear SuspensionOffset laydown single-shock
Front BrakesSingle 300 mm petal disc with dual-piston caliper, ABS
Rear BrakesSingle 250mm Disc with Single-Piston Caliper, ABS
Wheelbase1, 575 mm
Fuel Capacity14 L
Overall Length2310 mm
Overall Height1100 mm
Fuel SystemDFI® with 38mm Keihin Throttle Bodies (2)

Summary

General Information

Before Servicing

Precautionary measures before starting inspection, disassembly, or reassembly of general parts.

Model Identification

Identification of different model views and frame/engine numbers for EN650AF/BF.

Specifications

Detailed specifications for EN650AF/BF including dimensions, engine, fuel system, and performance.

Unit Conversion Table

Table providing conversion factors for various units of measurement.

Periodic Maintenance

Periodic Maintenance Chart

Scheduled maintenance tasks based on year and odometer readings.

Torque and Locking Agent

Table listing tightening torque and remarks for major fasteners.

Specifications

Standard and service limit specifications for various motorcycle systems.

Special Tools

List of specialized tools required for maintenance procedures.

Fuel System (DFI)

Exploded View

Exploded view illustration of the DFI system components.

DFI System

Overview and components of the Digital Fuel Injection system.

Special Tools and Sealant

List of specialized tools and sealants for DFI system maintenance.

DFI System Troubleshooting Guide

Guide for diagnosing and resolving problems with the DFI system.

Cooling System

Coolant Flow Chart

Diagram illustrating the flow of coolant through the system.

Specifications

Standard and service limit specifications for cooling system components.

Coolant

Information on coolant type, level, draining, filling, and pressure testing.

Engine Top End

Specifications

Standard and service limit specifications for engine top end parts.

Cylinder Head Cover

Procedures for removing and installing the cylinder head cover.

Camshaft, Camshaft Chain

Procedures for removing, installing, and inspecting camshafts and the chain.

Cylinder Head

Procedures for measuring cylinder compression and removing/installing the cylinder head.

Valves

Procedures for inspecting, adjusting, removing, and installing valves and related components.

Cylinder, Pistons

Procedures for removing and installing cylinders, pistons, and piston rings.

Clutch

Specifications

Standard and service limit specifications for clutch components.

Clutch Lever and Cable

Procedures for inspecting, adjusting, and servicing the clutch lever and cable.

Clutch

Procedures for removing, installing, and inspecting clutch components.

Clutch Plate Assembly Inspection

Inspection and adjustment procedures for clutch plates.

Engine Lubrication System

Specifications

Standard and service limit specifications for engine oil and oil pressure.

Engine Oil and Oil Filter

Procedures for inspecting and changing engine oil and oil filter.

Oil Pumps

Procedures for removing, installing, and inspecting oil pumps.

Oil Pressure Measurement

Procedures for measuring engine oil pressure.

Engine Removal/Installation

Engine Removal

Step-by-step procedure for removing the engine from the motorcycle.

Engine Installation

Step-by-step procedure for installing the engine into the motorcycle.

Crankshaft/Transmission

Specifications

Standard and service limit specifications for crankshaft and connecting rod components.

Crankcase Splitting

Procedures for splitting the crankcase halves.

Crankshaft and Connecting Rods

Procedures for removing, installing, and inspecting crankshaft and connecting rods.

Transmission

Procedures for removing, installing, and disassembling the transmission assembly.

Final Drive

Specifications

Standard and service limit specifications for drive chain and sprockets.

Drive Chain

Procedures for inspecting, adjusting, lubricating, removing, installing, and replacing the drive chain.

Sprocket, Coupling

Procedures for removing, installing, inspecting, and lubricating sprockets and coupling.

Brakes

Specifications

Standard and service limit specifications for brake components.

Brake Lever, Brake Pedal

Procedures for adjusting and removing/installing brake lever and pedal.

Calipers

Procedures for removing, installing, disassembling, and inspecting brake calipers.

Brake Pads

Procedures for removing, installing, and inspecting brake pads for wear.

Master Cylinder

Procedures for removing, installing, disassembling, and inspecting master cylinders.

Brake Disc

Procedures for removing, installing, and inspecting brake discs for wear and warp.

Brake Fluid

Procedures for inspecting and changing brake fluid, including bleeding the lines.

Anti-Lock Brake System (Equipped Models)

Information on ABS system parts, diagnosis, and troubleshooting.

Suspension

Specifications

Standard and service limit specifications for suspension components.

Front Fork

Procedures for removing, installing, changing oil, disassembling, and assembling front forks.

Rear Shock Absorber

Procedures for adjusting spring preload, removing, installing, and inspecting rear shock absorbers.

Swingarm

Procedures for removing, installing, inspecting, and lubricating swingarm bearings.

Tie-Rod, Rocker Arm

Procedures for removing, installing, and inspecting tie-rods and rocker arms.

Steering

Special Tools

List of specialized tools for steering system maintenance.

Steering Stem

Procedures for removing, installing, and inspecting steering stem and bearings.

Handlebars

Procedures for removing and installing handlebars and related components.

Frame

Frame Inspection

Visual inspection of the frame for cracks, dents, bending, or warp.

Battery Case

Procedures for removing and installing the battery case and related electrical components.

Footpeg

Procedures for removing and installing front and rear footpeg assemblies.

Side Stand

Procedures for removing and installing the side stand and its switch.

Electrical System

Specifications

Standard and service limit specifications for electrical components.

Precautions

Important precautions to follow when servicing electrical systems.

Battery

Procedures for removing, installing, activating, and inspecting the battery.

Charging System

Procedures for removing, installing, and inspecting the charging system components.

Ignition System

Procedures for removing, installing, and inspecting ignition system components like crankshaft sensor and stick coils.

Electric Starter System

Procedures for removing, installing, disassembling, and assembling the starter motor.

Lighting System

Procedures for replacing headlight bulbs and servicing lighting system components.

Switches and Sensors

Procedures for inspecting and testing various switches and sensors.

Meter, Gauge, Indicator Unit

Procedures for removing, installing, disassembling, inspecting, and setting meter unit functions.

Relay Box

Procedures for removing, installing, and inspecting the relay box and its circuits.

Fuses

Procedures for removing, installing, and inspecting fuses.

Appendix

Cable, Wire, and Hose Routing

Diagrams and instructions for routing cables, wires, and hoses on the motorcycle.

Troubleshooting Guide

Common problems and their potential causes and remedies for various motorcycle systems.

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