Kawasaki Vulcan 2000 (VN2000) - Repair, Service Manual and Electrical Wiring Diagrams

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KAWASAKI VULCAN 2000 (VN2000) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual / Repair Manualand Wiring Diagrams for motorcycles Kawasaki Vulcan 2000 (VN2000).

 
CONTENTS:

Foreword
General Information
- Before starting to perform an inspection service or carry out a
- VN2000-A1 (US, and Canada) Left Side View:
- VN2000-A1 (US, and Canada) Right Side View:
- VN2000-A1 (Europe) Left Side View:
- VN2000-A1 (Europe) Right Side View:
- Overview
- An automatic decompressor (Automatic Compression Reliese) system
- Dual balancers harmonize primary balance and reduce vibration.
- Prefixes for Units:
- Units of Temperature:
Periodic Maintenance
- The scheduled maintenance must be done in accordance with this c
- The following tables list the tightening torque for the major fa
- Inside Circlip Pliers: 57001–143
- Steering Stem Nut Wrench: 57001–1100
- Jack: 57001–1238
- Oil Filter Wrench: 57001–1249
- Spark Plug Wrench, Hex 16: 57001–1262
- Jack Attachment : 57001–1571
- Drive Belt Tension Gauge: 57001– 1585
- Steering System:
Fuel System (DFI)
- Oil Pressure Gauge, 5 kg/cm² : 57001–125
- Fork Oil Level Gauge : 570101–1290
- Hand Tester : 57001–1394
- Fuel Pressure Gauge Adapter : 57001–1593
- Needle Adapter Set : 57001–1457
- Kawasaki Bond (Silicone Sealant) : 56019–120
- Throttle Sensor Setting Adapter: 57001–1400
- Fuel Hoses: 57001–1607
- DFI System Wiring Diagram
- There are a number of important precautions that should be follo
- Outline
- NOTE
- Self-diagnosis Outline
- The main throttle sensor is a rotating variable resistor that ch
- Removal
- Removal/Installation
- Removal/Installation
- Removal
- Start the engine and switch the diagnosis mode to Dealer 1 mode
- Camshaft Position Sensor Removal/Installation
- Speed Sensor Removal/Installation
- Gear Position Switch Removal/Installation
- Vehicle-down Sensor Removal
- The subthrottle sensor is a rotating variable resistor that chan
- Oxygen Sensor Removal/Installation
- Fuel Injector ##1: Front Fuel Injector for Front Cylinder (Servic
- Fuel Pump Removal
- Ignition Coil ##1: Ignition Coil for Front Cylinder (Service Code
- Starter Control Relay Removal and Installation
- Radiator Fan Relay Removal/Installation
- Subthrottle Valve Actuator Removal
- Air Switching Valve Removal/Instalation
- Decompression Solenoid Removal/Installation
- Oxygen Sensor Heater Removal/Installation
- Subthrottle Motor Driver Removal/Installation
- Oxygen Sensor Removal/Installation
- Inspection Flow Chart
- ECU Removal
- Fuel Pressure Inspection
- Throttle Grip Free Play Inspection
- Idle Speed Check
- Element Removal
- Fuel Tank Removal
- The Evaporative Emission Control System for California Model rou
Cooling System
- Permanent type antifreeze is used as a coolant to protect the co
- Bearing Driver Set : 57001–1129
- Bearing Remover Shaft : 57001–1265
- Bearing Remover Head, ϕ10 x ϕ12 : 57001–1266
- Coolant Deterioration Inspection
- Water Pump Removal
- WARNING
- Thermostat Removal
- Hose Installation
Engine Top End
- Cam Height
- Push Rod Length and Runout
- Valve Head Thickness
- Valve Stem Bend
- Camshaft Journals
- Valve Guide Reamer, ϕ6 : 57001–1596
- Valve Guide Arbor, ϕ5.7 : 57001–1564
- Compression Gauge : 57001–221
- Valve Spring Compressor Assembly : 57001–241
- Valve Spring Compressor Adapter, ϕ28.2 : 57001–243
- Compression Gauge Adapter, M14 x 1.25 : 57001–1590
- Spark Plug Wrench, Hex 16 : 57001–1262
- Piston Ring Compressor Grip : 57001–1095
- Valve Seat Cutter, 45° – ϕ41.5 : 57001–1117
- Valve Seat Cutter, 32° – ϕ38.5 : 57001–1122
- Valve Seat Cutter, 60° – ϕ41 : 57001–1124
- Valve Seat Cutter Holder, ϕ6 : 57001–1576
- Valve Seat Cutter Holder Bar : 57001–1128
- Piston Ring Compressor Belt, ϕ95 ~ ϕ108 : 57001–1358
- Valve Seat Cutter 45° – ϕ40 : 57001–1496
- Valve Seat Cutter 32° – ϕ44 : 57001–1515
- Piston Pin Puller Assembly: 57001–1568
- Bearing Driver Set: 57001–1129
- Air Suction Valve Removal
- Rocker Case Cover Removal
- Rocker Case Removal
- Decompression Mechanism Removal
- Camshaft Removal
- Cylinder Compression Measurement
- Cylinder Removal
- Upper Muffler Removal
Clutch
- Clutch Holder: 57001–1243
- Flywheel & Pulley Holder: 57001–1343
- Flywheel & Pulley Holder Adapter: 57001–1547
- Kawasaki Bond (Liquid Gasket-Black): 92104–1064
- Lever Free Play Inspection
- Outer Clutch Cover Removal
Engine Lubrication System
- Oil Pressure Gauge, 5 kg/cm² : 57001–125
- Oil Pressure Gauge Adapter, PT 1/8 : 57001–1033
- Oil Filter Wrench : 57001–1249
- Kawasaki Bond (Silicone Sealant) : 56019–120
- Because of the semi-dry sump lubrication system, the engine oil
- Oil Pump Removal
- Oil Pan Removal
- Oil Pressure Measurement
Engine Removal/Installation
- Jack : 57001–1238
- Socket Wrench: 57001–1347
- Jack Attachment: 57001–1571
- Engine Removal
Crankshaft/Transmission
- Outside Circlip Pliers : 57001–144
- Gear Holder : 57001–1574
- Bearing Driver Set : 57001–1129
- Flywheel & Pulley Holder : 57001–1343
- Kawasaki Bond (Liquid Gasket – Black) : 92104–1064
- Flywheel & Pulley Holder Adapter 57001–1547
- Crankcase　Disassembly
- Connecting Rod Removal
- Balancer Mechanism Removal
- Shift Pedal Removal
- Ball Bearing and Outer Race Replacement
Wheels/Tires
- Inside Circlip Pliers : 57001–143
- Bearing Driver Set : 57001–1129
- Jack : 57001–1238
- Bearing Remover Head, 20 x 22 : 57001–1293
- Bearing Remover Head, 25 x 28 : 57001–1346
- Bearing Remover Shaft, 13 : 57001–1377
- Jack Attachment : 57001–1571
- Front Wheel Removal
- Air Pressure Inspection/Adjustment
- Hub Bearings Removal
Final Drive
- Inside Circlip Priers : 57001–143
- Oil Seal & Bearing Remover: 57001–1058
- Bearing Driver Set : 57001–1129
- Pulley Holder : 57001–1572
- Grip : 57001–1591
- The drive belt must be checked, and adjusted in accordance with
- Engine Pulley Cover Removal
Brakes
- Inside Circlip Pliers: 57001–143
- Brake Lever Position Adjustment
- Front Caliper Removal
- Front Brake Pad Removal
- Front Master Cylinder Removal
- Brake Disc Removal
- Brake Fluid Level Inspection
- Brake Hose Removal/Installation
Suspension
- Inside Circlip Pliers: 57001–143
- Fork Cylinder Holder Handle : 57001–183
- Fork Cylinder Holder Adapter : 57001–1057
- Oil Seal & Bearing Remover : 57001–1058
- Bearing Driver Set : 57001–1129
- Jack : 57001–1238
- Fork Oil Level Gauge : 570101–1290
- Jack Attachment : 57001–1571
- Hook Wrench : 57001–1580
- Fork Oil Seal Driver, 49 : 57001–1589
- Fork Oil Change
- Rebound Damping Force Adjustment
- Swingarm Removal
Steering
- Head Pipe Outer Race Press Shaft : 57001–1075
- Head Pipe Outer Race Driver : 57001–1077
- Head Pipe Outer Race Remover : 57001–1107
- Steering Stem Nut Wrench : 57001–1100
- Steering Stem Bearing Driver : 57001–1344
- Steering Stem Bearing Driver Adapter : 57001–1345
- Handlebar Removal
- Steering Check
- Steering Stem Removal
- Stem Bearing Removal
Frame
- Jack: 57001–1238
- Jack Attachment: 57001–1571
- Rear Seat Removal
- Right Side Cover Removal
- Front Fender Removal
- Tool Case Removal
- Right Footboard Removal
- Downtube Removal
- Headlight Cover Removal
- Frame Inspection
Electrical System
- Spark Plug Wrench, Hex 16 : 57001–1262
- Jack : 57001–1238
- Hand Tester : 57001–1394
- Flywheel & Pulley Holder: 57001–1343
- Filler Cap Driver : 57001–1454
- Needle Adapter Set: 57001–1457
- Flywheel & Pulley Holder Adapter: 57001–1547
- Jack Attachment : 57001–1571
- Left Handlebar Switches [A]
- There are a number of important precautions that should be follo
- Wiring Inspection
- Battery Removal
- Alternator Rotor Removal
- Starter Motor Removal
- This model adopts the daylight system and has a headlight relay
- Automobiles use a turn signal canceling system actuated by steer
- Fan Motor Inspection
- Meter Unit Removal
- Air Switching Valve Operation Test
- Decompression Solenoid Inspection
- Fuel Level Sensor Inspection
- The relay box [A] has relays and diodes. The relays and diodes c
- Main Fuse Removal
Appendix
- NOTE