Kawasaki VULCAN VN750 TWIN Motorcycle Service Manual – PDF DOWNLOAD

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Kawasaki VULCAN VN750 TWIN Motorcycle Service Manual – PDF DOWNLOAD

FILE DETAILS:

Kawasaki VULCAN VN750 TWIN Motorcycle Service Manual – PDF DOWNLOAD 

Language : English
Pages : 2395
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Kawasaki VULCAN VN750 TWIN Motorcycle Service Manual – PDF DOWNLOAD 

Vulcan 750 Manual 0
Cover 1
Quick Reference Guide 2
Safety Instructions & List of Abbreviations 4
Emission Control Information 5
Foreword 7
1 – General Information 9
Before Servicing 10
Model Identification 12
General Specifications 14
Periodic Maintenance Chart 16
2 – Fuel System 17
Exploded View 18
Specifications 20
Throttle Grip and Cables 21
Throttle Grip Play Inspection 21
Throttle Cable Play Adjustment 21
Throttle Cable Removal 22
Throttle Cable Installation Notes 23
Throttle Cable Lubrication 24
Choke Cable 24
Choke Cable Free Play Inspection 24
Choke Cable Adjustment 25
Choke Cable Installation 25
Choke Cable Lubrication 25
Choke Cable Inspection 25
Carburetors 25
Idle Speed Inspection 25
Idle Speed Adjustment 26
High Altitude Performance Adjustment 26
Carburetor Synchronization Inspection 26
Carburetor Synchronization 27
Fuel Level Inspection 27
Fuel Level Adjustment 28
Fuel System Cleanliness Inspection 29
Carburetor Removal 29
Carburetor Installation Notes 30
Carburetor Separation 32
Carburetor Disassembly Notes 33
Carburetor Assembly Notes 34
Carburetor Cleaning 36
Carburetor Inspection 37
Air Cleaner 38
Air Cleaner Element Removal 38
Air Cleaner Element Installation 39
Air Cleaner Element Inspection and Replacement 39
Air Cleaner Element Cleaning 39
Air Cleaner Housing Removal 40
Air Cleaner Assembly 40
Surge Tank 41
Surge Tank Removal 41
Fuel Tank 41
Fuel Tank Removal 41
Fuel Tap Installation 41
Fuel Tap Assembly Note 42
Fuel Tank and Tap Cleaning 42
Fuel Tank and Cap Inspection 42
Fuel Tap Inspection 42
Evaporative Emission Control System 43
Parts Removal/Installation Notes 43
Hose Inspection 43
Separator Inspection 43
Separator Operation Test 43
Canister Inspection 44
3 – Cooling System 45
Exploded View 46
Specifications 47
Cooling System 47
Coolant 48
Coolant Level Inspection 48
Coolant Inspection 48
Coolant Draining 48
Coolant Filling 50
Air Bleeding 50
Visual Leak Inspection 51
Cooling System Pressure Testing 51
Cooling System Flushing 51
Disassembly and Assembly Precautions 52
Radiator 52
Radiator Removal 52
Radiator Installation Note 53
Radiator Hose, Reservoir Tank Hose Installation Notes 53
Radiator Hose, Reservoir Tank Hose Inspection 53
Radiator Inspection 54
Radiator Cleaning Notes 54
Radiator Cap Inspection 54
Thermostat 55
Thermostat Cover Removal 55
Thermostat Installation Note 55
Thermostat Inspection 55
Water Pump, Mechanical Seal 56
Pump Impeller Removal 56
Pump Impeller Installation Notes 56
Pump Impeller Inspection 56
Mechanical Seal Removal 56
Mechanical Seal Installation Notes 57
Mechanical Seal Inspection 57
4 – Engine Top End 59
Exploded View 60
Specifications 63
Special Tools 65
Clean Air System (US and Switzerland models) 66
Vacuum Switch Valve Removal 66
Clean Air System Hose Installation 66
Air Suction Valve Installation Note 66
Vacuum Switch Valve Test 67
Air Suction Valve Inspection 67
Cylinder Head Cover 68
Front Cylinder Head Cover Removal 68
Rear Cylinder Head Cover Removal Notes 68
Cylinder Head Cover Installation Notes 68
Cam Chain Tensioner and Cam Chain Tension Spring 69
Front Cam Chain Tensioner Removal 69
Cam Chain Tensioner Installation 69
Replacement Chain Tensioner Installation 70
Rear Chain Tensioner Removal Notes 70
Upper Chain Tension Spring Removal 70
Upper Chain Tension Spring Installation 70
Camshaft, Camshaft Chain 70
Camshafts Removal 70
Camshafts Installation Notes 71
Front Camshaft Chain Timing Procedure 73
Rear Camshaft Chain Timing Procedure 76
Camshaft Chain Timing Inspection 78
Camshaft Bearing Clearance Inspection 78
Upper/Lower Camshaft Chain Wear 79
Camshaft Chain Guide Wear 79
Hydraulic Lash Adjuster (HLA) 80
HLA Removal 80
HLA Installation 80
HLA Air Bleeding 80
HLA Leak-down Measurement 81
HLA Troubleshooting Guide 82
Cylinder Head 84
Compression Measurement 84
Cylinder Head Removal 84
Cylinder Head Installation Notes 85
Cylinder Head Disassembly 86
Cylinder Head Cleaning 86
Cylinder Head Assembly 86
Cylinder Head Warp 87
Valves 88
Valve Clearance Inspection 88
Valve Seat Inspection 88
Valve Seat Repair 88
Measuring Valve-to-Guide Clearance (Wobble method) 90
Cylinder, Piston 92
Front Cylinder Block Removal 92
Rear Cylinder Block Removal Notes 93
Cylinder Block Installation Notes 93
Piston Removal Notes 94
Piston Installation Notes 95
Cylinder Inside Diameter 96
Cylinder Boring, Honing 96
Piston Diameter Measurement 97
Piston Ring, Piston Ring Groove Wear 97
Piston Ring End Gap 97
Exhaust System 98
Muffler Assembly Removal 98
Muffler Assembly Installation Notes 98
Right Exhaust Pipe Removal 98
Left Exhaust Pipe Removal 99
Exhaust Pipe Installation Notes 99
Muffler Removal Notes 100
Muffler Installation Notes 101
Front Exhaust Manifold Removal 101
Rear Exhaust Manifold Removal 101
Exhaust Manifold Installation 101
5 – Clutch 103
Exploded View 104
Specifications 105
Special Tools 105
Clutch 106
Clutch Level Play Adjustment 106
Clutch Cable Removal 107
Clutch Cable Installation 107
Clutch Release Removal 108
Clutch Release Installation Notes 108
Clutch Plates/Clutch Hub Removal 109
Clutch Plates/Clutch Hub Installation Notes 110
Right Engine Cover Removal 111
Right Engine Cover Installation Notes 111
Clutch Disassembly 112
Clutch Assembly 112
Friction Plate Wear, Damage Inspection 112
Friction or Steel Plate Warp Inspection 113
Clutch Spring Free Length Measurement 113
Clutch Housing Finger Inspection 113
Clutch Hub Spline Inspection 114
6 – Engine Lubrication System 115
Exploded View 116
Engine Oil Flow Chart 117
Specifications 118
Special Tools 118
Engine Oil, Oil Filter and Oil Pump Screen 119
Engine Oil Level Inspection 119
Engine Oil Change and Oil Pump Screen Cleaning 119
Oil Filter Removal 120
Oil Filter Installation Notes 121
Oil Pump 121
Oil Pressure Measurement 121
Oil Pump Chain Slack Inspection 122
Oil Pump Disassembly 122
Oil Pump Assembly Notes 123
Oil Pump Outer Rotor/Inner Rotor Clearance 124
Oil Pump Outer Rotor/Pump Body Clearance 124
Oil Pump Rotor Side Clearance 125
Oil Pipe and Relief Valve 125
Outside Oil Pipe Removal 125
Outside Oil Pipe and Installation Notes 126
Relief Valve and Left Side Oil Pipe Removal 126
Relief Valve and Left Side Oil Pipe Installation Notes 126
Relief Valve Inspection 126
Oil Passage Cover and Inside Oil Pipe Removal/Installation 127
7 – Engine Removal/Installation 128
Exploded View 129
Engine Removal/Installation 130
Engine Removal 130
Engine Installation Notes 131
8 – Crankshaft/Transmission 132
Exploded View 133
Specifications 135
Special Tools 136
Crankcase Splitting 137
Crankcase Splitting 137
Crankcase Disassembly 138
Crankcase Assembly 140
Right Balancer Bearing Installation 142
Crankshaft/Connecting Rods 142
Crankshaft Removal 142
Crankshaft Installation Notes 142
Connecting Rod Removal 143
Connecting Rod Installation Notes 143
Crankshaft/Connecting Rod Cleaning 143
Connecting Rod Bend/Twist 144
Connecting Rod Big End Side Clearance 144
Connecting Rod Big End Bearing Insert/Crankpin Wear 145
Crankshaft Runout 146
Crankshaft Main Bearing Insert/Journal Wear 146
Crankshaft Side Clearance 147
Balancer 148
Left Balancer Removal 148
Left Balancer Installation 148
Right Balancer Removal 149
Right Balancer Installation Notes 149
Right Balancer Disassembly/Assembly 150
Balancer Damper Inspection 150
Transmission 151
External Shift Mechanism Removal 151
External Shift Mechanism Installation 151
External Shift Mechanism Disassembly Note 153
External Shift Mechanism Assembly Notes 153
External Shift Mechanism Inspection 153
Transmission Shaft Removal 154
Transmission Shaft Installation Notes 154
Transmission Shaft Disassembly 154
Transmission Shaft Assembly Notes 155
Shift Drum Removal 155
Shift Drum Installation Note 156
Shift Fork Bending 156
Shift Fork/Gear Groove Wear 156
Shift Fork Guide Pin Wear 157
Shift Drum Groove Wear 157
Gear Dog/Gear Dog Hole Damage 157
Ball and Needle Bearing Wear 157
9 – Wheels/Tires 158
Exploded View 159
Specifications 160
Special Tools 160
Wheel (Rims) 161
Front Wheel Removal 161
Front Wheel Installation Notes 161
Rear Wheel Removal 162
Rear Wheel Installation 162
Wheel Inspection 162
Axle Inspection 163
Wheel Balance Check 163
Wheel Balance Adjustment 164
Balancer Weight Installation 164
Balancer Weight Removal 165
Tires 165
Tire Removal 165
Tire Installation 166
Tire Inspection 167
Tire Repair 168
Hub Bearings 168
Front Hub Bearing Removal 168
Rear Hub Bearing Removal 169
Front or Rear Hub Bearing Installation 170
Front Hub Bearing Lubrication, Inspection 170
Rear Hub Bearing Inspection 171
Speedometer Gear Housing 171
Speedometer Gear Housing Installation 171
Speedometer Gear Housing Disassembly 171
Speedometer Gear Housing Assembly 172
Speedometer Gear Assembly Lubrication 172
Special Tools (Addition) 173
10 – Final Drive 174
Exploded View 175
Specifications 177
Special Tools 177
Final Gear Case Oil 179
Final Gear Case Oil Level Inspection 179
Final Gear Case Oil Change 179
Final Bevel Gears 179
Final Gear Case Removal 179
Final Gear Case Installation Notes 180
Final Gear Case Disassembly 181
Final Gear Case Assembly Notes 182
Pinion Gear Disassembly 183
Pinion Gear Assembly 184
Ring Gear Assembly 184
Final Bevel Gear Adjustment 185
Bevel Gear Inspection 188
Pinion Gear Bearing Inspection 188
Oil Seal Inspection 188
Propeller Shaft 188
Propeller Shaft Removal 188
Propeller Shaft Installation 189
Propeller Shaft Joint Lubrication 189
Propeller Shaft Joint Inspection 189
Propeller Shaft Inspection 189
Front Bevel Gears Removal/Disassembly 190
Front Bevel Gear Case Removal 190
Front Bevel Gear Case Installation Notes 190
Front Bevel Gear Case Assembly Notes 191
Damper Cam Removal 191
Damper Cam Installation Notes 192
Front Driven Gear Removal 192
Front Driven Gear Installation Notes 193
Front Drive Gear Removal 193
Front Drive Gear Installation 194
Front Drive Gear Assembly Note 194
Front Bevel Gear Adjustment 195
Bearing Installation Adjustment 196
Backlash Adjustment 197
Tooth Contact Adjustment 198
Front Bevel Gears Inspection 199
Bevel Gear Inspection 199
Bevel Gear Bearing Inspection 199
Oil Seal Inspection 199
Cam Damper Inspection 200
11 – Brakes 201
Exploded View 202
Specifications 203
Special Tool 203
Brake Adjustment 204
Front Brake Adjustment 204
Rear Brake Pedal Position Adjustment 204
Rear Brake Pedal Free Play Adjustment 204
Rear Brake Lining Wear Inspection 204
Rear Brake Cam Lever Angle Adjustment 205
Calipers 205
Front Caliper Removal 205
Caliper Installation Notes 206
Caliper Disassembly Notes 206
Caliper Assembly Notes 206
Fluid Seal Damage 206
Dust Seal and Cover Damage 206
Piston, Cylinder Damage 206
Caliper Holder Shaft Wear 206
Brake Pads 207
Pad Removal 207
Pads Installation Notes 207
Lining Wear 207
Master Cylinder 208
Front Master Cylinder Removal 208
Front Master Cylinder Installation Notes 208
Inspection and Adjustment After Installation 208
Front Master Cylinder Disassembly Notes 208
Front Master Cylinder Assembly Notes 209
Master Cylinder Inspection 209
Discs 209
Disc Wear 209
Disc Cleaning 210
Disc Warp 210
Brake Fluid 210
Fluid Level Inspection 210
Brake Fluid Recommendation 211
Brake Fluid Change 211
Bleeding the Brake Line 211
Brake Hoses 213
Brake Hose Inspection 213
Brake Hose Replacement 213
Rear Brake Cable 213
Rear Brake Cable Removal 213
Rear Brake Cable Installation Notes 213
Brake Panel 214
Brake Panel Disassembly 214
Brake Panel Assembly Notes 214
Brake Panel Camshaft Lubrication 215
Brake Pedal 215
Brake Pedal/Shaft Removal 215
Brake Pedal/Shaft Installation Notes 217
12 – Suspension 218
Exploded View 219
Specifications 220
Special Tools 220
Front Fork 221
Air Pressure Adjustment (VN700-A1 and VN750-A1 ~ A4 221
Fork Oil Changing 222
Front Fork Removal (each fork leg) 223
Front Fork Installation Notes 223
Front Fork Disassembly 224
Front Fork Assembly 225
Inner Tube Inspection 226
Oil Seal and Dust Seal Inspection 226
Rear Shock Absorber 226
Air Pressure Adjustment 226
Damping Force Adjustment 227
Rear Shock Absorber Removal 228
Rear Shock Absorber Installation Note 228
Rear Shock Absorber Inspection 228
Rear Shock Absorber Oil Filling 228
Rear Shock Scrapping 229
Swing Arm 229
Swing Arm Removal 229
Swing Arm Installation and Alignment 230
Swing Arm Disassembly Notes 231
Swing Arm Assembly Note 232
Swing Arm Bearing Inspection 232
Swing Arm Lubrication 232
13 – Steering 233
Exploded View 234
Special Tools 235
Steering Adjustment 236
Steering Inspection 236
Steering Adjustment 236
Steering Removal/Installation 237
Steering Stem Removal 237
Steering Stem Installation Notes 238
Steering Maintenance 240
Steering Stem Bearing Lubrication 240
Bearing Wear, Damage 240
Grease Seal Deterioration, Damage 240
Steering Stem Warp 240
Handlebar 240
Handlebar Removal 240
Handlebar Installation Notes 241
14 – Frame 243
Exploded View 244
Subframe 246
Subframe Removal 246
Subframe Installation Notes 246
Seat 247
Seat Removal 247
Seat Installation Note 247
Fenders 247
Front Fender Removal 247
Front Fender Installation Note 248
Rear Fender Removal 248
15 – Electrical System 249
Exploded View 252
Specifications 255
Special Tools 256
Precautions 257
Battery 257
Precautions 257
Electrolyte Level Inspection 258
Battery Condition 258
Battery Initial Charging 259
Battery Ordinary Charging 259
Battery Test Charging 260
Battery Case Removal 261
Battery Case Installation 262
Battery Vent Hose Routing 262
Charging System 262
Inside Alternator Cover Removal 263
Inside Alternator Cover Installation Notes 263
Alternator Rotor Removal 263
Alternator Rotor Installation Notes 264
Regulator/Rectifier Output Voltage Measurement 265
Regulator/Rectifier Output Current Measurement 265
Stator Coil Resistance Measurement 265
Stator Coil Insulation Test 266
Regulator/Rectifier Inspection 266
Ignition System 267
Ignition System Troubleshooting 268
Safety Instructions 269
Spark Plug Removal/Installation Note 269
Spark Plug Cleaning and Inspection 269
Spark Plug Gap 269
Ignition Coil Installation Notes 269
Ignition Coil Arcing Distance Measurement 270
Ignition Coil Resistance Measurement 270
Ignition Timing Inspection (Dynamic) 271
IC Ignitor Inspection 271
Outside Alternator Cover Removal 272
Outside Alternator Cover Installation Note 273
Pickup Coil Removal 273
Pickup Coil Installation Notes 273
Pickup Coil Inspection 274
Electric Starter System 274
Starter Motor Removal 274
Starter Motor Installation Notes 275
Starter Motor Disassembly 275
Starter Motor Assembly 276
Yoke Assembly Note 277
Electric Starter System Inspection Caution 277
Starter Relay Inspection 277
Brush Inspection 278
Brush Spring Inspection 278
Commutator Cleaning and Inspection 278
Armature Inspection 279
Brush Plate Inspection 279
Brush and Lead Assembly Inspection 279
Torque Limiter Installation Note 279
Torque Limiter Inspection 280
Starter Clutch Removal 280
Starter Clutch Installation 280
Starter Clutch Disassembly 280
Starter Clutch Assembly Notes 280
Starter Clutch Inspection 280
Lighting System 281
Headlight Beam Horizontal Adjustment 281
Headlight Beam Vertical Adjustment 281
Headlight Removal 281
Headlight Bulb Replacement Notes 282
Headlight Unit Installation Notes 282
Tail/Brake Light and License Plate Light Bulb Replacement Notes 283
Lighting System Inspection Note 283
Headlight Reserve Lighting Sytem Inspection 285
Turn Signal Circuit 285
Turn Signal Light Bulb Replacement 285
Turn Signal Relay Inspection 287
Automatic Cancelling Distance Sensor Inspection (VN700A and VN750-A1, A2, A3, A4 Models) 287
Cooling Fan System 288
Radiator Fan Removal 288
Fan System Circuit Inspection 288
Fan Motor Inspection 289
Fan Relay Inspection 289
Fan Switch Inspection 289
Meters and Gauges 290
Meter Panel Removal 290
Meter Panel Disassembly 291
Tachometer Unit Disassembly 291
Tachometer Unit Assembly 291
Bulb Replacement Notes 292
Tachometer Inspection 292
Fuel Gauge Unit Removal Note 293
Fuel Gauge Unit Installation Note 293
Fuel Gauge Operation Inspection 293
Water Temperatiure Gauge Operation Inspection 294
Switches and Sensors 294
Rear Brake Light Switch Inspection 294
Rear Brake Light Switch Adjustment 295
Rear Brake Light Switch Removal 295
Switch Inspection 295
Fuel Level Sensor Installation 296
Fuel Level Sensor Inspection 296
Water Temperature Sensor Removal Note 297
Water Temperature Sensor Installation Note 297
Water Temperature Sensor Inspection 297
Junction Box 298
Fuse Removal 298
Fuse Installation Note 299
Fuse Inspection 299
Junction Box Fuse Circuit Inspection 299
Fan, Starter Relay and Headlight Relay Inspection 299
Diode Circuit Inspection 300
Electrical Wiring 300
Wiring Inspection 300
Wiring Diagram 301
16 – Appendix 309
Troubleshooting Guide 310
General Lubrication 314
Lubrication 314
Nut, Bolt, and Fastener Tightness 314
Tightness Inspection 314
Standard Torque Table 315
Unit Conversion Table 316
17 – Supplement-2000 Model 317
Foreword 318
General Information 319
General Specifications 319
Wheels/Tires 321
Specifications 321
Tire 322
Tire Inspection 322
18 – Supplement-2001 Model 323
Foreword 324
General Information 325
General Specifications 325
Periodic Maintenance Chart 327
Electrical System 329
VN750-A16 Wiring Diagram (U S A and Canada) 329
Back Cover – Model Application (VINs) 331
VN750 Parts Diagrams All Years 0
1986 – A2 0
Air Filter 332
Brake Pedal – Torque Link 334
Cables 336
Camshafts – Tensioners 338
Carburetor Parts 340
Carburetor 342
Chassis Electrical Equipment 344
Clutch 346
Crankcase 348
Crankshaft 350
Cylinders – Pistons 352
Cylinder Head Cover 354
Cylinder Head 356
Decals 358
Drive Shaft – Final Gear 360
Engine Covers 362
Engine Mount 364
Fenders 366
Footrests 368
Frame Fittings 370
Frame 372
Front Bevel Gear 374
Front Brake 376
Front Forks 378
Front Master Cylinder 380
Front Wheel 382
Fuel Evaporative System 384
Fuel Tank 386
Gear Change Drum – Shift Forks 388
Gear Change Mechanism 390
Generator 392
Handlebar 394
Headlight 396
Ignition Switch – Locks – Reflectors 398
Ignition System 400
Labels 402
Meters 404
Mufflers 406
Oil Pump – Oil Filter 408
Owner’s Tools 410
Publications 412
Radiator – Cooling System 413
Rear Wheel 416
Seat 418
Side Covers 420
Stands 422
Starter Motor 424
Suspension – Shock Absorber 426
Swingarm 428
Taillights 430
Tires 432
Transmission 434
Turn Signals 436
Valves 438
1987 – A3 0
Air Filter 440
Battery Case 442
Brake Pedal – Torque Link 444
Cables 446
Camshafts – Tensioners 448
Carburetor Parts 450
Carburetor 452
Chassis Electrical Equipment 454
Clutch 456
Crankcase 458
Crankshaft 460
Cylinders – Pistons 462
Cylinder Head Cover 464
Cylinder Head 466
Decals 468
Drive Shaft – Final Gear 470
Engine Covers 472
Engine Mount 474
Fenders 476
Footrests 478
Frame 480
Front Bevel Gear 482
Front Brake 484
Front Forks 486
Front Master Cylinder 488
Front Wheel 490
Fuel Evaporative System 492
Fuel Tank 494
Gear Change Drum – Shift Forks 496
Gear Change Mechanism 498
Generator 500
Handlebar 502
Headlight 504
Ignition Switch – Locks – Reflectors 506
Ignition System 508
Labels 510
Meters 512
Mufflers 514
Oil Pump – Oil Filter 516
Owner’s Tools 518
Publications 520
Radiator – Cooling System 521
Rear Wheel 524
Seat 526
Side Covers 528
Stands 530
Starter Motor 532
Suspension – Shock Absorbers 534
Swingarm 536
Taillights 538
Tires 540
Transmission 542
Turn Signals 544
Valves 546
1988 – A4 0
Air Filter 548
Battery Case 550
Brake Pedal – Torque Link 552
Cables 554
Camshafts – Tensioners 556
Carburetor Parts 558
Carburetor 560
Chassis Electrical Equipment 562
Clutch 564
Crankcase 566
Crankshaft 568
Cylinders – Pistons 570
Cylinder Head Cover 572
Cylinder Head 574
Decals 576
Drive Shaft – Final Gear 578
Engine Covers 580
Fenders 582
Footrests 584
Frame Fittings 586
Frame 588
Front Bevel Gear 590
Front Brake 592
Front Forks 594
Front Master Cylinder 596
Front Wheel 598
Fuel Evaporative System 600
Fuel Tank 602
Gear Change Drum – Shift Forks 604
Gear Change Mechanism 606
Generator 608
Handlebar 610
Headlight 612
Ignition Switch – Locks – Reflectors 614
Ignition System 616
Labels 618
Meters 620
Mufflers 622
Oil Pump – Oil Filter 624
Owner’s Tools 626
Publications 628
Radiator – Cooling System 629
Rear Wheel 632
Seat 634
Side Covers 636
Stands 638
Starter Motor 640
Suspension – Shock Absorbers 642
Swingarm 644
Taillights 646
Tires 648
Transmission 650
Turn Signals 652
Valves 654
1989 – A5 0
Air Filter 656
Brake Pedal – Torque Link 658
Cables 660
Camshafts – Tensioners 662
Carburetor Parts 664
Carburetor 666
Chassis Electrical Equipment 668
Clutch 670
Crankcase 672
Crankshaft 674
Cylinders – Pistons 676
Cylinder Head Cover 678
Cylinder Head 680
Decals 682
Drive Shaft – Final Gear 684
Engine Covers 686
Engine Mount 688
Fenders 690
Footrests 692
Frame Fittings 694
Frame 696
Front Bevel Gear 698
Front Brake 700
Front Forks 702
Front Master Cylinder 704
Front Wheel 706
Fuel Evaporative System 708
Fuel Tank 710
Gear Change Drum – Shift Forks 712
Gear Change Mechanism 714
Generator 716
Handlebar 718
Headlight 720
Ignition Switch – Locks – Reflectors 722
Ignition System 724
Labels 726
Meters 728
Mufflers 730
Oil Pump – Oil Filter 732
Owner’s Tools 734
Publications 736
Radiator – Cooling System 737
Rear Wheel 740
Seat 742
Side Covers 744
Stands 746
Starter Motor 748
Suspension – Shock Absorbers 750
Swingarm 752
Taillights 754
Tires 756
Transmission 758
Turn Signals 760
Valves 762
1990 – A6 0
Air Filter 764
Brake Pedal – Torque Link 766
Cables 768
Camshafts – Tensioners 770
Carburetor Parts 772
Carburetor 774
Chassis Electrical Equipment 776
Clutch 778
Crankcase 780
Crankshaft 782
Cylinders – Pistons 784
Cylinder Head Cover 786
Cylinder Head 788
Decals (Red – Red)(VN750-A6 – A7) 790
Drive Shaft – Final Gear 792
Engine Covers 794
Engine Mount 796
Fenders 798
Footrests 800
Frame Fittings 802
Frame 804
Front Bevel Gear 806
Front Brake 808
Front Forks 810
Front Master Cylinder 812
Front Wheel 814
Fuel Evaporative System 816
Fuel Tank 818
Gear Change Drum – Shift Forks 820
Gear Change Mechanism 822
Generator 824
Handlebar 826
Headlight 828
Ignition Switch – Locks – Reflectors 830
Ignition System 832
Labels 834
Meters 836
Mufflers 838
Oil Pump – Oil Filter 840
Owner’s Tools 842
Publications 844
Radiator – Cooling System 845
Rear Wheel 848
Seat 850
Side Covers 852
Stands 854
Starter Motor 856
Suspension – Shock Absorbers 858
Swingarm 860
Taillights 862
Tires 864
Transmission 866
Turn Signals 868
Valves 870
1991 – A7 0
Air Filter 872
Brake Pedal – Torque Link 874
Cables 876
Camshafts – Tensioners 878
Carburetor Parts 880
Carburetor 882
Chassis Electrical Equipment 884
Clutch 886
Crankcase 888
Crankshaft 890
Cylinders – Pistons 892
Cylinder Head Cover 894
Cylinder Head 896
Decals 898
Drive Shaft – Final Gear 900
Engine Covers 902
Engine Mount 904
Fenders 906
Footrests 908
Frame Fittings 910
Frame 912
Front Bevel Gear 914
Front Brake 916
Front Forks 918
Front Master Cylinder 920
Front Wheel 922
Fuel Evaporative System 924
Fuel Tank 926
Gear Change Drum – Shift Forks 928
Gear Change Mechanism 930
Generator 932
Handlebar 934
Headlight 936
Ignition Switch – Locks – Reflectors 938
Ignition System 940
Labels 942
Meters 944
Mufflers 946
Oil Pump – Oil Filter 948
Owner’s Tools 950
Publications 952
Radiator – Cooling System 953
Rear Wheel 956
Seat 958
Side Covers 960
Stands 962
Starter Motor 964
Suspension – Shock Absorbers 966
Swingarm 968
Taillights 970
Tires 972
Transmission 974
Turn Signals 976
Valves 978
1992 – A8 0
Air Filter 980
Brake Pedal – Torque Link 982
Cables 984
Camshafts – Tensioner 986
Carburetor Parts 988
Carburetor 990
Chassis Electrical Equipment 992
Clutch 994
Crankcase 996
Crankshaft 998
Cylinders – Pistons 1000
Cylinder Head Cover 1002
Cylinder Head 1004
Decal (Blue – Gray)(VN750 – A8 – A9) 1006
Decal (Green – Green)(VN750 – A8 – A9) 1008
Drive Shaft – Final Gear 1010
Engine Covers 1012
Engine Mount 1014
Fenders 1016
Footrests 1018
Frame Fittings 1020
Frame 1022
Front Bevel Gear 1024
Front Brake 1026
Front Forks 1028
Front Master Cylinder 1030
Front Wheel 1032
Fuel Tank 1036
Fuel Evaporative System 1034
Gear Change Drum – Shift Forks 1038
Gear Change Mechanism 1040
Generator 1042
Handlebar 1044
Headlight 1046
Ignition Switch – Locks – Reflectors 1048
Ignition System 1050
Labels 1052
Meters 1054
Mufflers 1056
Oil Pump – Oil Filter 1058
Owner’s Tools 1060
Publications 1062
Radiator – Cooling System 1063
Rear Wheel 1066
Seat 1068
Side Covers 1070
Stands 1072
Starter Motor 1074
Suspension – Shock Absorbers 1076
Swingarm 1078
Taillights 1080
Tires 1082
Transmission 1084
Turn Signals 1086
Valves 1088
1993 – A9 0
Air Filter 1090
Brake Pedal – Torque Link 1092
Cables 1094
Camshafts – Tensioner 1096
Carburetor Parts 1098
Carburetor 1100
Chassis Electrical Equipment 1102
Clutch 1104
Crankcase 1106
Crankshaft 1108
Cylinders – Pistons 1110
Cylinder Head Cover 1112
Cylinder Head 1114
Decal (Blue – Gray)(VN750 – A8 – A9) 1116
Decal (Green – Green)(VN750 – A8 – A9) 1118
Drive Shaft – Final Gear 1120
Engine Covers 1122
Engine Mount 1124
Fenders 1126
Footrests 1128
Frame Fittings 1130
Frame 1132
Front Bevel Gear 1134
Front Brake 1136
Front Forks 1138
Front Master Cylinder (VN750-A7 – A8 – A9) 1140
Front Wheel 1142
Fuel Evaporative System 1144
Fuel Tank 1146
Gear Change Drum – Shift Forks 1148
Gear Change Mechanism 1150
Generator 1152
Handlebar 1154
Headlight 1156
Ignition Switch – Locks – Reflectors 1158
Ignition System 1160
Labels 1162
Meters 1164
Mufflers 1166
Oil Pump – Oil Filter 1168
Owner’s Tools 1170
Publications 1172
Radiator – Cooling System 1173
Rear Wheel 1176
Seat 1178
Side Covers 1180
Stands 1182
Starter Motor 1184
Suspension – Shock Absorbers 1186
Swingarm 1188
Taillights 1190
Tires 1192
Transmission 1194
Turn Signals 1196
Valves 1198
1994 – A10 0
Air Filter 1200
Brake Pedal – Torque Link 1202
Cables 1204
Camshafts – Tensioner 1206
Carburetor Parts 1208
Carburetor 1210
Chassis Electrical Equipment 1212
Clutch 1214
Crankcase 1216
Crankshaft 1218
Cylinders – Pistons 1220
Cylinder Head Cover 1222
Cylinder Head 1224
Decals (Green – Blue) 1226
Decals (Red – Red) 1228
Drive Shaft – Final Gear 1230
Engine Covers 1232
Engine Mount 1234
Fenders 1236
Footrests 1238
Frame Fittings 1240
Frame 1242
Front Bevel Gear 1244
Front Brake 1246
Front Forks 1248
Front Master Cylinder 1250
Front Wheel 1252
Fuel Evaporative System 1254
Fuel Tank 1256
Gear Change Drum – Shift Forks 1258
Gear Change Mechanism 1260
Generator 1262
Handlebar 1264
Headlight 1266
Ignition Switch – Locks – Reflectors 1268
Ignition System 1270
Labels 1272
Meters 1274
Mufflers 1276
Oil Pump – Oil Filter 1278
Owner’s Tools 1280
Publications 1282
Radiator – Cooling System 1283
Rear Wheel 1286
Seat 1288
Side Covers 1290
Stands 1292
Starter Motor 1294
Suspension – Shock Absorbers 1296
Swingarm 1298
Taillights 1300
Tires 1302
Transmission 1304
Turn Signals 1306
Valves 1308
1995 – A11 0
Air Filter 1310
Brake Pedal – Torque Link 1312
Cables 1314
Camshafts – Tensioners 1316
Carburetor Parts 1318
Carburetor 1320
Chassis Electrical Equipment 1322
Clutch 1324
Crankcase 1326
Crankshaft 1328
Cylinders – Pistons 1330
Cylinder Head Cover 1332
Cylinder Head 1334
Decals (Green – Blue) 1336
Decals (Red – Red) 1338
Drive Shaft – Final Gear 1340
Engine Covers 1342
Engine Mount 1344
Fenders 1346
Footrests 1348
Frame Fittings 1350
Frame 1352
Front Bevel Gear 1354
Front Brake 1356
Front Forks 1358
Front Master Cylinder 1360
Front Wheel 1362
Fuel Evaporative System 1364
Fuel Tank 1366
Gear Change Drum – Shift Forks 1368
Gear Change Mechanism 1370
Generator 1372
Handlebar 1374
Headlight 1376
Ignition Switch – Locks – Reflectors 1378
Ignition System 1380
Labels 1382
Meters 1384
Mufflers 1386
Oil Pump – Oil Filter 1388
Owner’s Tools 1390
Publications 1392
Radiator – Cooling System 1393
Rear Wheel 1396
Seat 1398
Side Covers 1400
Stands 1402
Starter Motor 1404
Suspension – Shock Absorbers 1406
Swingarm 1408
Taillights 1410
Tires 1412
Transmission 1414
Turn Signals 1416
Valves 1418
1996 – A12 0
Air Filter 1420
Brake Pedal – Torque Link 1422
Cables 1424
Camshafts – Tensioners 1426
Carburetor Parts 1428
Carburetor 1430
Chassis Electrical Equipment 1432
Clutch 1434
Crankcase 1436
Crankshaft 1438
Cylinders – Pistons 1440
Cylinder Head Cover 1442
Cylinder Head 1444
Decals (Blue – Silver) 1446
Decals (Red – Gray) 1448
Drive Shaft – Final Gear 1450
Engine Covers 1452
Engine Mount 1454
Fenders 1456
Footrests 1458
Frame Fittings 1460
Frame 1462
Front Bevel Gear 1464
Front Brake 1466
Front Forks 1468
Front Master Cylinder 1470
Front Wheel 1472
Fuel Evaporative System 1474
Fuel Tank 1476
Gear Change Drum – Shift Forks 1478
Gear Change Mechanism 1480
Generator 1482
Handlebar 1484
Headlight 1486
Ignition Switch – Locks – Reflectors 1488
Ignition System 1490
Labels 1492
Meters 1494
Mufflers 1496
Oil Pump – Oil Filter 1498
Owner’s Tools 1500
Publications 1502
Radiator – Cooling System 1503
Rear Wheel 1506
Seat 1508
Side Covers 1510
Stands 1512
Starter Motor 1514
Suspension – Shock Absorbers 1516
Swingarm 1518
Taillights 1520
Tires 1522
Transmission 1524
Turn Signals 1526
Valves 1528
1997 – A13 0
Air Filter 1530
Brake Pedal – Torque Link 1532
Cables 1534
Camshafts – Tensioners 1536
Carburetor Parts 1538
Carburetor 1540
Chassis Electrical Equipment 1542
Clutch 1544
Crankcase 1546
Crankshaft 1548
Cylinders – Pistons 1550
Cylinder Head Cover 1552
Cylinder Head 1554
Decals (Ebony – Silver) 1556
Decals (Red – Gray) 1558
Drive Shaft – Final Gear 1560
Engine Covers 1562
Engine Mount 1564
Fenders 1566
Footrests 1568
Frame Fittings 1570
Frame 1572
Front Bevel Gear 1574
Front Brake 1576
Front Forks 1578
Front Master Cylinder 1580
Front Wheel 1582
Fuel Evaporative System 1584
Fuel Tank 1586
Gear Change Drum – Shift Forks 1588
Gear Change Mechanism 1590
Generator 1592
Handlebar 1594
Headlight 1596
Ignition Switch – Locks – Reflectors 1598
Ignition System 1600
Labels 1602
Meters 1604
Mufflers 1606
Oil Pump – Oil Filter 1608
Owner’s Tools 1610
Publications 1612
Radiator – Cooling System 1613
Rear Wheel 1616
Seat 1618
Side Covers 1620
Stands 1622
Starter Motor 1624
Suspension – Shock Absorbers 1626
Swingarm 1628
Taillights 1630
Tires 1632
Transmission 1634
Turn Signals 1636
Valves 1638
1998 – A14 0
Air Filter 1640
Brake Pedal – Torque Link 1642
Cables 1644
Camshafts – Tensioners 1646
Carburetor Parts 1648
Carburetor 1650
Chassis Electrical Equipment 1652
Clutch 1654
Crankcase 1656
Crankshaft 1658
Cylinder – Pistons 1660
Cylinder Head Cover 1662
Cylinder Head 1664
Decals 1666
Drive Shaft – Final Gear 1668
Engine Covers 1670
Engine Mount 1672
Fenders 1674
Footrests 1676
Frame Fittings 1678
Frame 1680
Front Bevel Gear 1682
Front Brake 1684
Front Forks 1686
Front Master Cylinder 1688
Front Wheel 1690
Fuel Evaporative System 1692
Fuel Tank 1694
Gear Change Drum – Shift Forks 1696
Gear Change Mechanism 1698
Generator 1700
Handlebar 1702
Headlight 1704
Ignition Switch – Locks – Reflectors 1706
Ignition System 1708
Labels 1710
Meters 1712
Mufflers 1714
Oil Pump – Oil Filter 1716
Owner’s Tools 1718
Publications 1720
Radiator 1721
Rear Wheel 1724
Seat 1726
Side Covers 1728
Stands 1730
Starter Motor 1732
Suspension – Shock Absorbers 1734
Swingarm 1736
Taillights 1738
Tires 1740
Transmission 1742
Turn Signals 1744
Valves 1746
1999 – A15 0
Air Filter 1748
Untitled 1750
Brake Pedal – Torque Link 1750
Cables 1752
Camshafts – Tensioners 1754
Carburetor Parts 1756
Carburetor 1758
Chassis Electrical Equipment 1760
Clutch 1762
Crankcase 1764
Crankshaft 1766
Cylinders – Pistons 1768
Cylinder Head Cover 1770
Cylinder Head 1772
Decals 1774
Drive Shaft – Final Gear 1776
Engine Covers 1778
Engine Mount 1780
Fenders 1782
Footrests 1784
Frame Fittings 1786
Frame 1788
Front Bevel Gear 1790
Front Brake 1792
Front Forks 1794
Front Master Cylinder 1796
Front Wheel 1798
Fuel Evaporative System 1800
Fuel Tank 1802
Gear Change Drum – Shift Forks 1804
Gear Change Mechanism 1806
Generator 1808
Handlebar 1810
Headlight 1812
Ignition Switch – Locks – Reflectors 1814
Ignition System 1816
Labels 1818
Meters 1820
Mufflers 1822
Oil Pump – Oil Filter 1824
Owner’s Tools 1826
Publications 1828
Radiator – Cooling System 1829
Rear Wheel 1832
Seat 1834
Side Covers 1836
Stands 1838
Starter Motor 1840
Suspension – Shock Absorbers 1842
Swingarm 1844
Taillights 1846
Tires 1848
Transmission 1850
Turn Signals 1852
Valves 1854
2000 – A16 0
Air Filter 1856
Brake Pedal – Torque Link 1858
Cables 1860
Camshaft(s) – Tensioner 1862
Carburetor 1864
Carburetor Parts 1864
Chassis Electrical Equipment 1866
Clutch 1868
Crankcase 1872
Crankshaft 1874
Cylinders – Pistons 1876
Cylinder Head 1878
Cylinder Head Covers 1881
Decals VN750-A15 A16 1882
Drive Shaft – Final Gear 1884
Engine Covers 1886
Engine Mount 1888
Fenders 1890
Footrests 1892
Frame 1894
Frame Fittings 1896
Front Bevel Gear 1898
Front Brake 1900
Front Fork 1902
Front Master Cylinder 1904
Front Wheel 1906
Fuel Evaporative System(CA) 1908
Fuel Tank A15 – A18 1910
Gear Change Drum – Shift Forks 1912
Gear Change Mechanism 1914
Generator 1916
Handlebar 1918
Headlight 1920
Ignition Switch – Locks – Reflectors 1922
Ignition System 1924
Labels 1926
Meters 1928
Mufflers 1930
Oil Pump – Filter 1932
Owner’s Tools 1934
Pubs 1936
Radiator – Cooling System 1937
Rear Wheel 1940
Seat 1942
Side Covers 1944
Stands 1946
Starter Motor 1948
Suspension – Shock Absorber 1950
Swingarm 1952
Taillights 1954
Tires 1956
Transmission 1958
Turn Signals 1960
Valves 1962
2001 – A17 0
Air Filter 1964
Brake Pedal – Torque Link 1966
Cables 1968
Camshafts – Tensioner 1970
Carburetor Parts 1972
Carburetor 1974
Chassis Electrical Equipment 1976
Clutch 1978
Crankcase 1980
Crankshaft 1982
Cylinders – Pistons 1984
Cylinder Head Cover 1986
Cylinder Head 1988
Decals 1990
Drive Shaft – Final Gear 1992
Engine Covers 1994
Engine Mount 1996
Fenders 1998
Footrests 2000
Frame Fittings 2002
Frame 2004
Front Bevel Gear 2006
Front Brake 2008
Front Fork 2010
Front Master Cylinder 2012
Front Wheel 2014
Fuel Evaporative System (CA) 2016
Fuel Tank 2018
Gear Change Drum – Shift Forks 2020
Gear Change Mechanism 2022
Generator 2024
Handlebars 2026
Headlight 2028
Ignition Switch – Locks – Reflector 2030
Ignition System 2032
Labels 2034
Meters 2036
Mufflers 2038
Oil Pump – Oil Filter 2040
Owner’s Tools 2042
Publications 2044
Radiator – Cooling System 2045
Rear Wheel 2048
Seat 2050
Side Covers 2052
Stands 2054
Starter Motor 2056
Suspension – Shock Absorber 2058
Swingarm 2060
Taillight 2062
Tires 2064
Transmission 2066
Turn Signals 2068
Valves 2070
2002 – A18 0
Air Filters 2072
Brake Pedal – Torque Link 2074
Cables 2076
Camshafts – Tensioner 2078
Carburetor Parts 2080
Carburetor 2082
Chassis Electrical Equipment 2084
Clutch 2086
Crankcase 2088
Crankshaft 2090
Cylinders – Pistons 2092
Cylinder Head Cover 2094
Cylinder Head 2096
Decals 2098
Drive Shaft – Final Gear 2100
Engine Covers 2102
Engine Mount 2104
Fenders 2106
Footrests 2108
Frame Fittings 2110
Front Bevel Gear 2114
Front Brake 2116
Front Forks 2118
Front Master Cylinder 2120
Front Wheel 2122
Fuel Evaporative System (CA) 2124
Fuel Tank 2126
Gear Change Drum – Shift Forks 2128
Gear Change Mechanism 2130
Generator 2132
Handlebar 2134
Headlight 2136
Ignition Switch – Locks – Reflectors 2138
Ignition System 2140
Labels 2142
Meters 2144
Mufflers 2146
Oil Pump – Oil Filter 2148
Owner’s Tools 2150
Publications 2152
Radiator – Cooling System 2153
Rear Wheel 2156
Seat 2158
Side Covers 2160
Stands 2162
Starter Motor 2164
Suspension – Shock Absorbers 2166
Swingarm 2168
Taillights 2170
Tires 2172
Transmission 2174
Turn Signals 2176
Valves 2178
2003 – A19 0
Air Filter 2180
Brake Pedal – Torque Link 2182
Cables 2184
Camshafts – Tensioners 2186
Carburetor Parts 2188
Carburetor 2190
Chassis Electrical Equipment 2192
Clutch 2194
Crankcase 2196
Crankshaft 2198
Cylinders – Pistons 2200
Cylinder Head Cover 2202
Cylinder Head 2204
Decals 2206
Drive Shaft – Final Gear 2208
Engine Covers 2210
Engine Mount 2212
Fenders 2214
Footrests 2216
Frame Fittings 2218
Frame 2220
Front Bevel Gear 2222
Front Brake 2224
Front Forks 2226
Front Master Cylinder 2228
Front Wheel 2230
Fuel Evaporative System (CA) 2232
Fuel Tank 2234
Gear Change Drum – Shift Forks 2236
Gear Change Mechanism 2238
Generator 2240
Handlebar 2242
Headlight 2244
Ignition Switch – Locks – Reflectors 2246
Ignition System 2248
Labels 2250
Meters 2252
Mufflers 2254
Oil Pump – Oil Filter 2256
Owner’s Tools 2258
Publications 2260
Radiator – Cooling System 2261
Rear Wheel 2264
Seat 2266
Side Covers 2268
Stands 2270
Starter Motor 2272
Suspension – Shock Absorbers 2274
Swing Arm 2276
Taillights 2278
Tires 2280
Transmission 2282
Turn Signals 2284
Valves 2286
2004 – A20 0
Air Filter 2288
Brake Pedal – Torque Link 2290
Cables 2292
Camshafts – Tensioners 2294
Carburetor Parts 2296
Carburetor 2298
Chassis Electrical Equipment 2300
Clutch 2302
Crankcase 2304
Crankshaft 2306
Cylinders – Pistons 2308
Cylinder Head Cover 2310
Cylinder Head 2312
Decals (Ebony – Silver) 2314
Drive Shaft – Final Gear 2316
Engine Covers 2318
Engine Mount 2320
Fenders 2322
Footrests 2324
Frame Fittings 2326
Frame 2328
Front Bevel Gear 2330
Front Brake 2332
Front Forks 2334
Front Master Cylinder 2336
Front Wheel 2338
Fuel Evaporative System (CA) 2340
Fuel Tank 2342
Gear Change Drum – Shift Forks 2344
Gear Change Mechanism 2346
Generator 2348
Handlebar 2350
Headlight 2352
Ignition Switch – Locks – Reflectors 2354
Ignition System 2356
Labels 2358
Meters 2360
Mufflers 2362
Oil Pump – Oil Filter 2364
Owner’s Tools 2366
Publications 2368
Radiator – Cooling System 2369
Rear Wheel 2372
Seat 2374
Side Covers 2376
Stands 2378
Starter Motor 2380
Suspension – Shock Absorbers 2382
Swingarm 2384
Taillights 2386
Tires 2388
Transmission 2390
Turn Signals 2392
Valves 2394

DESCRIPTION:

Kawasaki VULCAN VN750 TWIN Motorcycle Service Manual – PDF DOWNLOAD 

FOREWORD:

• This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance andrepair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry outmaintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
• In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures  before starting work, and then do the work carefullyin a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.
• For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this servicemanual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

S.V 16/03/2025