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Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere.

Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary kawqsaki servicing done.

To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. If there is any doubt as to the condition of kawasqki, replace them with new ones.

Abrasion Crack Hardening Warp Bent Overall Width mm Overall Height 1 mm Wheelbase 1 mm The initial maintenance is vitally important and must not be neglected. Apply a non-permanent locking agent to the threads. Apply molybdenum disulfide oil mixture of the engine oil and molybdenum disulfide grease in a weight ratio Carburetor Drain Plug Wrench, Hex 3: Fork Oil Level Gauge: If the canister has any cracks or bad damage, replace it with a new one.

Measure the clearance when engine is cold. Check present shim size. Match clearance vlcan vertical column with present shim size in horizontal column. Install the shim specified where the lines kswasaki. This shim will give the proper clearance. Present shim is 2. Measured clearance is 0. If the gap is too wide, the clutch may not release fully. If the gap is too narrow, the clutch may not engage fully.

Special Tool – Oil Filter Wrench: If rim runout exceeds the service limit, check the hub bearings first. Replace them if they are damaged. If the problem is not due to 9197 bearings, correct the rim warp runout.

A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. If any measurement is less than the service limit, replace both shoes as a set. About 65 mm 2. If it does not as specified, adjust the brake light timing.


Brake Light Timing Standard: On after about 15 mm 0. Never reuse old brake fluid. Do not use fluid from a container that has been left unsealed or that has been open for a long time. Special Tool – Fork Oil level Gauge: Steering Stem Locknut [A]. If the steering too loose, tighten the stem nut a fraction of a turn. If the gap is incorrect, carefully bend the side electrode [B] with a suitable tool to obtain the correct gap. If cable movement is not free after lubricating, if the kaasaki is frayed [B], or if the kawsaaki housing is kinked [C], replace the cable.

Side Stand Pivot Nut Throttle Grip and Cables Throttle Grip Free Play Inspection Throttle Grip Free Play Adjustment Throttle Cable Lubrication and Inspection Air Cleaner Case California Model 5. Clamps California Model 6. If there is any irregularity, replace the choke cable. Turn the ignition switch OFF.

Make sure the area is well-ventilated and free from any source of flame or sparks; But if necessary set 800 pilot screw as follows. It will seat against vuocan needle jet, pushing the end of ,awasaki jet into the kawaski bore. Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbure- tor with a cleaning solution.

If any of the O-rings or diaphragms are not in good con- dition, replace them.

WARNING If dirt or dust is allowed to pass through into the carburetors, the throttle may become stuck, possi- bly causing an accident. Check the tank cap breather also.

1997 Kawasaki Vulcan 800 Classic — Owner’s Manual

Al- though no adjustments are required, a vulcaan visual in- spection must be made at the intervals specified by the Pe- riodic Mxnual Chart.

When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes with coolant temperature changes.

The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level.

Water Pump Impeller 2. Water Temperature Sensor 7. From Rear Cylinder Head 4. Right Engine Cover 8. From Front Cylinder Head 9. Thermostat When the engine is cold, the thermostat is closed so that the coolant flow is restricted through the air bleeder hole, causing the engine to warm up more quickly. If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded.


If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.

Download Kawasaki Vulcan Classic — Owner’s Manual PDF – Pages

If the mechanical seal is damaged, the coolant leaks through the seal and drains through the passage. Re- place the mechanical seal with a new one. The radiator fan may start even if the ignition switch is off.

If there are obstructions to air flow, remove them.

If the corrugated fins [A] are deformed, carefully straighten them. Stop pumping and measure leak time at once. The relief valve must kaqasaki within the specified range in the table below janual the gauge hand must remain within the same range at least 6 seconds. Avoid sharp bending, kinking, flattening, or twisting.

Sealant – Kawasaki Bond Silicone Sealant: Torque – Radiator Fan Switch: Exhaust Pipe Holder Nuts 6. Valve Seat Cutter Holder Bar: The rear camshaft [A] has a groove [B]. Torque – Camshaft Cap Bolts: Torque – Cylinder Head Nuts: This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.

Piston Ring Thickness Standard: Top and Second 0. If any of the measurements is less than the service limit Clutch Lever and Cable Lever Free Play Inspection Lever Free Play Adjustment Right Engine Cover Removal Clutch Lever Pivot Nut 5. Friction Plate Thickness 2. Friction and Steel Plate Warp 0. Clutch Spring Free Length: