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Kawasaki Vulcan 1700 Voyager 2009 2010 Service Manual

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🏷️ Basic Information Identification Make: Kawasaki Model: Vulcan 1700 Voyager Years Covered: 2009, 2010 Codes Product Type: Workshop Service Manual Delivery Method: PDF Download 👋 Introduction Market Position Segment: Full-size...
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Type: Motorcycle
Vendor:
Sku: 69672
Kawasaki Vulcan 1700 Voyager 2009 2010 Service Manual
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Vulcan 1700 Voyager
Years Covered:
2009, 2010
Codes
Product Type:
Workshop Service Manual
Delivery Method:
PDF Download
👋 Introduction
Market Position
Segment:
Full-size Grand American Tourer
Target Audience:
Long-distance touring riders seeking comfort, storage, and performance.
Competitive Analysis
Competitors:
Harley-Davidson Electra Glide, Honda Gold Wing, Indian Roadmaster.
Key Features
Engine:
Powerful 1700cc liquid-cooled V-twin engine, renowned for its torque and smooth power delivery.
Touring Amenities:
Integrated hard saddlebags, large fairing with windshield for weather protection, comfortable seating for rider and passenger, ample luggage capacity.
Ride Quality:
Air-assisted rear suspension for adjustable ride comfort and load carrying, stable chassis for highway cruising.
Electronics:
Cruise control, premium audio system (on some trims), ABS (Anti-lock Braking System).
📋 Manual Details
Coverage Areas
Primary Focus:
Repair and Maintenance
Scope:
Comprehensive workshop procedures
Page Count
Total Pages:
794
Manual Type
Type:
Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed disassembly, assembly, inspection, diagnosis, and repair procedures for the 1700cc V-twin engine.
Fuel System:
EFI system components, fuel pump, injectors, throttle body, fuel pressure testing, troubleshooting.
Ignition System:
Ignition timing, spark plugs, ignition coils, ECU control, diagnosis.
Transmission:
Clutch operation, gearbox disassembly, inspection, lubrication, repair of the 6-speed constant mesh transmission.
Drivetrain:
Final drive (belt drive) inspection, tension adjustment, replacement procedures.
Brakes:
Front and rear brake system components, hydraulic lines, master cylinders, calipers, disc inspection, pad replacement, bleeding procedures.
Suspension:
Front fork (telescopic) disassembly, seal replacement, oil levels, rear shock absorber adjustment and replacement.
Steering:
Handlebar assembly, steering head bearing inspection and adjustment, troubleshooting.
Electrical System:
Wiring diagrams, component testing (battery, starter, alternator, lights, horn, indicators), fuses, relays, ECU diagnostics.
Bodywork:
Fairing removal and installation, seat, luggage systems (saddlebags, top case), body panel repairs and adjustments.
Cooling System:
Liquid-cooled engine components, radiator, fan, thermostat, coolant replacement.
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, lubrication points, valve clearance checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, including symptom-based troubleshooting guides.
Repair:
Step-by-step instructions for component removal, overhaul, and reinstallation for all major systems.
Diagnostics:
Fault code lookup, diagnostic connector access, sensor testing, ECU function checks.
Specifications:
Torque values, clearance specifications, fluid capacities, electrical resistance values.
Wiring Diagrams:
Detailed and color-coded electrical schematics for all model variants.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including advanced diagnostics.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable, enabling quick access to specific information.
Print Quality
Quality:
Designed for clarity and readability when printed, with clear diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
SOHC, 4-valve per cylinder, V-twin
Displacement:
1700cc (103.7 cubic inches)
Bore X Stroke:
102.0 x 104.0 mm
Cooling System:
Liquid-cooled
Compression Ratio:
9.5:1
Performance
Horsepower:
Approximately 74 HP @ 5000 RPM (claimed)
Torque:
Approximately 107 lb-ft @ 3500 RPM (claimed)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual 36mm throttle bodies
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil Specifications
Engine Oil Type:
SAE 10W-40, API SG or higher, JASO MA certified
Engine Oil Capacity:
Approximately 4.7 US quarts (4.5 liters) with filter change
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Features
Clutch Type:
Wet, multi-disc
Final Drive:
Belt drive
Fluid Specifications
Transmission Oil Type:
SAE 80W-90 API GL-4 hypoid gear oil (refer to manual for specific Kawasakispecification)
Fluid Capacities
Transmission Oil Capacity:
Approximately 0.7 US quarts (0.7 liters)
📐 Dimensions
Exterior
Length:
Approx. 103.7 inches (2635 mm)
Width:
Approx. 39.2 inches (995 mm)
Height:
Approx. 59.1 inches (1500 mm)
Weights
Dry Weight:
Approx. 798 lbs (362 kg)
Wet Weight:
Approx. 859.8 lbs (390 kg) (fully fueled)
Wheels Tires
Front Tire:
130/70R18 M/C 63H
Rear Tire:
170/70R16 M/C 75H
Wheelbase:
Approx. 64.0 inches (1625 mm)
🛡️ Safety Features
Ratings
ABS:
Available ABS (Anti-lock Braking System) on select models/trims.
Active Features
Braking System:
Dual 300mm front discs with 4-piston calipers, Single 300mm rear disc with 2-piston caliper.
Passive Features
Lighting:
Halogen headlights, LED taillight, integrated front and rear turn signals.
💡 Technology Features
Infotainment
Audio System:
Integrated AM/FM radio with CD player and MP3 input (specific features vary by trim level).
Speakers:
Fairing-mounted speakers.
Driver Assistance
Cruise Control:
Electronic cruise control system.
Connectivity
Auxiliary Input:
1/8" (3.5mm) auxiliary audio input jack for external devices.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,700 miles (6,000 km) or 6 months, whichever comes first.
Air Filter Inspection:
Every 3,700 miles (6,000 km) or 6 months.
Spark Plug Replacement:
Refer to manual, typically around 7,500 miles (12,000 km).
Belt Tension Check:
Every 7,500 miles (12,000 km) or annually.
Brake Fluid Change:
Every 2 years or as per manual recommendation.
Fluid Specifications
Coolant Type:
Kawasaki Genuine Coolant or equivalent ethylene glycol-based coolant (50/50 mix with distilled water).
Fluid Capacities
Coolant Capacity:
Approx. 2.7 US quarts (2.6 liters)
Known Issues
Common Wear Items:
Belt drive wear, clutch wear (depending on riding style), suspension seals.
Electrical Component Reliability:
Generally reliable, but standard electrical maintenance (connections, grounds) is crucial.
Filter Part Numbers
Oil Filter P/N:
Kawasaki 16097-0004 (or equivalent like K&N KN-111, HiFlofiltro HF111)
Air Filter P/N:
Kawasaki 11013-0019 (or equivalent like K&N KT-1709)
📚 Vehicle History
Brand Heritage
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company.
Legacy:
Known for robust engineering and performance-oriented motorcycles across various segments.
Model Evolution
Lineage:
Part of the Vulcan cruiser family, evolved from earlier Vulcan models with increased displacement and touring focus.
Key Changes:
The 1700 series introduced in 2009 marked a significant upgrade in displacement and touring features for the Vulcan line.
Production
Manufacturing Location:
Japan (likely for core components/assembly, final assembly may vary by market)
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