User manual KAWASAKI VULCAN900 CLASSIC SERVICE MANUAL

[. . . ] VULCAN900 CLASSIC VULCAN900 CLASSIC LT VN900 CLASSIC Motorcycle Service Manual Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System This quick reference guide will assist you in locating a desired topic or procedure. ·Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. ·Refer to the sectional table of contents for the exact pages to locate the specific topic required. 1j 2j 3j 4j 5j 6j 7j 8j 9j 10 j 11 j 12 j 13 j 14 j 15 j 16 j Appendix 17 j VULCAN900 CLASSIC VULCAN900 CLASSIC LT VN900 CLASSIC Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd. , Japan. [. . . ] Replace the cylinder head gasket with a new one. · Install: · Oil Pipe [B] Chain Guide (White) [C] Knock Pins Cylinder Head Gasket [D] head · Temporary tighten the cylinder4]. nuts (M10) following the tightening sequence [1 · Tighten thecylinder head nuts following the tightening sequence [1 6]. Torque - Cylinder Head Nuts (M10)(Final): 49 N·m (5. 0 kgf·m, 36 ft·lb) Cylinder Head Nuts (M8): 25 N·m (2. 5 kgf·m, 18 ft·lb) Torque - Cylinder Head Nuts (M10)(First): kgf·m, 15 ft·lb) 20 N·m (2. 0 Cylinder Head Warp straightedge across · Lay a at several positions. the lower surface of the cylinder head a thickness to · Usestraightedgegauge [A]the measure the space between the [B] and head. Cylinder Head Warp Standard: Service Limit: ­­­ 0. 05 mm (0. 002 in. ) If the cylinder head is warped more than the service limit, replace it. If the cylinder head is warped less than the service limit, repair the head by rubbing the lower surface on emery paper secured to a surface plate (first No. 400). 5-26 ENGINE TOP END Valves Valve Clearance Inspection · Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment · Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal cylinder head (see Removal). · Remove the the rocker arm, andCylinder Head the shims. open then · Swingand record the shim locations soremove shims can that the Mark · be installed in their original positions. Using the valve spring compressor assembly, remove the valve. Special Tools - Valve Spring Compressor Assembly: 57001 -241 [A] Valve Spring Compressor Adapter, 22: 57001-1202 [B] Valve Installation the oil seal with a new one. · Replacethin coat of molybdenum disulfide grease to the Apply a · valve stem before valve installation. springs so · Install thepainted sidethat the closed coil end faces downwards or upwards. Valve Stem [A] Stem Oil Seal [B] Spring Seat [C] Spring [D] Retainer [E] Split Keepers [F] Valve Guide Removal · Remove: Valve Removal) Valve (see · Stem Oil Seal Spring Seat Heat the area around the valve guide to 120 150°C (248 302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. CAUTION Do not heat the cylinder head with a torch. Soak the cylinder head in oil and heat the oil. Special Tool - Valve Guide Arbor, 5: 57001-1203 ENGINE TOP END 5-27 Valves Valve Guide Installation · Apply oil to the valve guide outer surface before installation. around the · Heat the area 302°F) (seevalve guide hole to about 120 150°C (248 Valve Guide Removal). valve guide in the top of · Drive the guide arbor [A]. fromflange stopsthe head using the valve The the guide from going in too far. Special Tool - Valve Guide Arbor, 5: 57001-1203 with the · Reamif the valve guide reused. valve guide reamer [A] even the old guide is Special Tool - Valve Guide Reamer, 5: 57001-1204 Valve-to-Guide Clearance Measurement (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. Insert a new valve [A] into the guide [B] and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface. Move the stem back and forth [C] to measure valve/valve guide clearance. Repeat the measurement in a direction at a right angle to the first. If the reading exceeds the service limit, replace the guide. · · · The reading is not actual valve/valve guide clearance because the measuring point is above the guide. Valve/Valve Guide Clearance (Wobble Method) Standard: Exhaust Inlet Service Limit: Exhaust Inlet 0. 38 mm (0. 015 in. ) 0. 26 mm (0. 010 in. ) 0. 09 0. 17 mm (0. 0035 0. 0067 in. ) 0. 03 0. 11 mm (0. 012 0. 0043 in. ) NOTE 5-28 ENGINE TOP END Valves Valve Seat Inspection · Remove the valve (see Valve Removal). the valve [B] valve seating · Check the seat [C]. surface [A] between and valve Measure the outside diameter [D] of the seating pattern on the valve seat. [. . . ] Clamp the stator coil lead and oil pressure switch lead. After installed, bend the clamp to the alternator cover. Clamp the oil pressure switch lead and sidestand switch lead. After installed, bend the clamp to the alternator cover. [. . . ]