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Kawasaki VN800B Vulcan 800 Classic (1995 - 2005)

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The original Haynes Repair Manual - Based on a complete stripdown and rebuild of a vehicle

Kawasaki VN800B Vulcan 800 Classic (1995 - 2005)

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What's Covered
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This Kawasaki Vulcan Manual is 408 pages.

QUICK REFERENCE DATA

CHAPTER ONE / 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 / Mechanicâ??s tips / Ball bearing replacement / Seals / Riding safety / Storage / Specifications

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 checks / Pre-checks / Service intervals / Tires 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

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 / Specifications Specs

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

CHAPTER SIX / CLUTCH
Clutch cable / Clutch cover / Clutch / Clutch release assembly / Specifications Specs

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

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 models only) / Vacuum switch valve / Air suction valve / Exhaust system / Specifications Specs

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 / Specifications Specs

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

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 / Specifications Specs

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 / Specifications Specs

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 / Specifications Specs

CHAPTER FOURTEEN / FRAME
Seat / Frame side covers / Storage box / Tool box / Footpegs / Sidestand / Front fender / Rear fender / Frame / Specifications Specs

INDEX

WIRING DIAGRAMS

Models covered:
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 KAWASAKI VN800A Vulcan
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 KAWASAKI VN800B Vulcan Classic
VN 800 A B

Clymer Manuals Kawasaki Vulcan VN800A Manual
Clymer Manuals Kawasaki Vulcan VN800B Manual

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