Segment:
Cruiser Motorcycle
Target Audience:
Owners and technicians seeking detailed information for maintenance and repair of the Kawasaki Vulcan VN800.
Competitors:
Honda Shadow, Yamaha V-Star, Suzuki Intruder models of similar displacement and era.
Vehicle Appeal:
Classic cruiser styling, reliable V-twin engine, shaft drive for low maintenance, comfortable riding position.
Manual Value:
Essential for owners who want to perform their own maintenance, diagnose issues, or undertake repairs, saving on labor costs and ensuring proper upkeep.
Engine Mechanical:
Complete disassembly, inspection, and reassembly of the engine, including cylinder head, pistons, crankshaft, and valve train.
Fuel System:
Carburetor (VM/CV type) servicing, fuel pump, fuel lines, and fuel tank maintenance.
Ignition System:
Ignition coil testing, spark plug specifications, CDI unit troubleshooting.
Electrical System:
Wiring diagrams, lighting system, starter motor, charging system (alternator, regulator/rectifier), battery maintenance.
Transmission:
Gearbox disassembly, inspection, and reassembly, clutch service (friction plates, pressure plate, springs).
Drivetrain:
Shaft drive system maintenance, universal joints, final drive housing.
Suspension:
Front fork servicing (oil change, seal replacement), rear shock absorber adjustment and replacement.
Brakes:
Front and rear brake system maintenance, caliper service, master cylinder overhaul, brake fluid replacement.
Steering:
Handlebar removal, steering stem bearing inspection and adjustment.
Cooling System:
Engine oil cooling system inspection and fluid changes.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat maintenance.
Routine Maintenance:
Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment (if applicable, though VN800 uses shaft drive), tire pressure checks.
Engine Repair:
Piston ring replacement, valve adjustments, gasket replacement, timing chain inspection.
Carburetor Rebuild:
Complete disassembly, cleaning, and reassembly of the carburetor with jetting information and adjustment procedures.
Electrical Troubleshooting:
Diagnosis of common electrical faults using wiring diagrams, testing of components like ignition coils, starter solenoids, and charging systems.
Suspension Rebuild:
Front fork seal replacement, fork oil specification and level, rear shock absorber service.
Brake System Service:
Brake pad replacement, caliper piston cleaning, master cylinder overhaul, brake fluid bleeding procedures.
Shaft Drive Maintenance:
Gear oil change, lubrication of universal joints.
Troubleshooting Guides:
Diagnostic flowcharts for common problems like starting issues, poor engine performance, and electrical faults.
Depth:
Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds.
Diagnostic Level:
Advanced diagnostic procedures for electrical and mechanical systems.
Component Rebuild:
Detailed instructions for rebuilding major components like carburetors, engines, transmissions, and brake calipers.
Engine Type:
Four-stroke, V-twin, SOHC, 2 valves per cylinder
Displacement:
77.3 cubic inches (1261 cc)
Bore X Stroke:
85.0 x 75.0 mm
Cooling System:
Liquid-cooled (with oil cooler)
Horsepower:
Approximately 50-55 HP (at crank, depending on source and specific model year tuning)
Torque:
Approximately 60-65 lb-ft (at crank, depending on source and specific model year tuning)
Fuel Delivery:
Mikuni BSR32 carburetor (single, downdraft) for VN800 Classic; potentially dual carburetors on some Drifter variants (verify).
Fuel Tank Capacity:
Approximately 3.2 gallons (12 liters)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Ignition:
Digital CDI with electronic advance
Overall Length:
Approximately 93.1 inches (2365 mm) for VN800 Classic
Overall Width:
Approximately 34.3 inches (870 mm) for VN800 Classic
Overall Height:
Approximately 44.3 inches (1125 mm) for VN800 Classic
Wheelbase:
Approximately 64.0 inches (1625 mm)
Dry Weight:
Approximately 474 lbs (215 kg) for VN800 Classic
Wet Weight:
Approximately 509 lbs (231 kg) for VN800 Classic (with fluids)
Max Load:
Refer to owner's manual/service manual for specific weight limits.
Front Tire Size:
VN800 Classic: 130/90-16 M/C 67S; VN800 Drifter: Varies by year/trim, often 100/90-19.
Rear Tire Size:
VN800 Classic: 140/90-16 M/C 71S; VN800 Drifter: Varies by year/trim, often 170/80-15.
Front Brake Type:
Single Disc with 2-piston caliper
Rear Brake Type:
Drum brake
Wheel Type:
Spoked wheels
Oil Change Interval:
Every 3,000 miles (4,800 km) or 6 months, whichever comes first. Check manual for exact mileage.
Oil Filter Replacement:
With every oil change.
Spark Plug Replacement:
Refer to manual; typically around 10,000-15,000 miles.
Valve Adjustment Interval:
Refer to manual; often at higher mileages like 15,000-20,000 miles.
Engine Oil Type:
SAE 10W-40 API SG or higher motorcycle-specific oil.
Engine Oil Capacity:
Refer to manual; typically around 3.2 US quarts (3.0 liters) with filter change.
Brake Fluid Type:
DOT 3 or DOT 4 (verify in manual).
Fork Oil Type:
Refer to manual for viscosity and grade (e.g., SAE 10W).
Final Drive Gear Oil Type:
Refer to manual; often SAE 80W-90 gear oil.
Carburetor Issues:
Can become clogged with age, leading to rough idle or stalling. Diaphragm may need replacement.
Charging System:
Regulator/rectifier can fail over time, leading to battery charging issues. Stator can also degrade.
Shaft Drive Maintenance:
Requires periodic gear oil changes; neglect can lead to wear in the universal joint or final drive gears.
Clutch Adjustment:
Clutch cable adjustment is typically needed periodically to maintain proper engagement.
Kawasaki Legacy:
Kawasaki has a long history in motorcycle manufacturing, known for performance and reliability across various segments.
Vn800 Lineage:
The VN800 series was part of Kawasaki's 'Vulcan' cruiser line, designed to offer classic styling with modern engineering. It served as a popular mid-size cruiser.
Classic Vs Drifter:
The VN800 Classic emphasized traditional cruiser styling with a low seat and classic lines. The VN800 Drifter offered a more distinctive retro style, often with larger front wheels and a more 'bobbed' fender look.
Production Period:
Introduced in the early 1990s, with the VN800 Classic/Drifter generation spanning from 1995 to 2006. The 1999-2004 range falls within this established generation.
