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Kawasaki Vulcan 1700 Voyager 2009-2012 Service Repair Manual

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The Vulcan 1700 Voyager, including the Voyager ABS model, is a full-size American-style touring motorcycle designed for comfortable long-distance riding. Produced between 2009 and 2012, it features a powerful liquid-cooled,...
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Kawasaki Vulcan 1700 Voyager 2009-2012 Service Repair Manual
The Vulcan 1700 Voyager, including the Voyager ABS model, is a full-size American-style touring motorcycle designed for comfortable long-distance riding. Produced between 2009 and 2012, it features a powerful liquid-cooled, 4-stroke, 1700 cc V-twin engine delivering approximately 73 hp and 108 lb-ft of torque. Key selling points include comfortable touring ergonomics, ample storage capacity with integrated saddlebags, and advanced features such as electronic cruise control and an integrated audio system. Its robust engineering and V-twin power make it a strong contender in the touring segment, competing with models from Honda, Harley-Davidson, and Yamaha. This comprehensive service and repair manual provides detailed information for owners and technicians to maintain and repair the Vulcan 1700 Voyager. It covers all major systems, including the engine and powertrain, transmission and drivetrain, chassis and suspension, brakes (including ABS), and the electrical system, complete with wiring diagrams. The manual offers step-by-step procedures for routine maintenance, troubleshooting common issues, and complete disassembly and reassembly of components. With an estimated 600-800 pages, this English-language guide offers in-depth technical specifications and repair guidance, ensuring the vehicle remains in optimal condition.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Vulcan 1700 Voyager
Sub Model:
Voyager ABS
Codes
Model Codes Covered:
VN1700A, VN1700B (Voyager ABS)
👋 Introduction
Market Position
Model Segment:
Full-size American-style touring motorcycle.
Competitive Analysis
Key Competitors:
Honda Gold Wing, Harley-Davidson Electra Glide, Indian Roadmaster, Yamaha Star Venture.
Key Features
Primary Selling Points:
Comfortable touring ergonomics, powerful V-twin engine, ample storage, advanced features for long-distance riding.
📋 Manual Details
Coverage Areas
Years Covered:
2009, 2010, 2011, 2012
Page Count
Estimated Page Count:
Approximately 600-800 pages (typical for comprehensive service manuals)
Manual Type
Manual Type:
Service and Repair Manual (Workshop Manual)
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine And Powertrain:
Engine disassembly, assembly, tuning, cooling system, lubrication system, fuel system (EFI), ignition system, exhaust system.
Transmission And Drivetrain:
Clutch, gearbox, final drive (belt drive system), maintenance and repair procedures.
Chassis And Suspension:
Frame, front fork (telescopic), rear suspension (swingarm, shock absorbers), steering system, wheel bearings, alignment.
Brakes:
Hydraulic brake system (front and rear), brake pads, discs, calipers, master cylinders, ABS system (if equipped).
Electrical System:
Battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlights, taillights, signals), ignition coils, sensors, ECU, wiring diagrams, diagnostic codes.
Bodywork And Fittings:
Fairings, saddlebags, windshield, seat, fuel tank, controls, instrumentation, body panel removal and installation.
Procedures Included
Maintenance:
Regular scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, chain/belt adjustment, lubrication points, valve clearance checks.
Troubleshooting:
Diagnostic charts for common issues, fault code interpretation, step-by-step diagnostic procedures for electrical and mechanical problems.
Repair:
Complete disassembly and reassembly of all major components, component-specific repair instructions, torque specifications for all fasteners.
Disassembly And Assembly:
Detailed step-by-step guides for removing and reinstalling all vehicle components and systems.
Technical Depth
Depth Of Coverage:
Comprehensive: Covers everything from basic rider maintenance to complete engine rebuilds, complex electrical diagnostics, and advanced suspension tuning.
📊 Manual Specifications
File Format
File Quality:
High-resolution PDF, allowing for clear viewing and printing of diagrams and text.
Searchability:
Likely searchable text for quick access to specific information.
Print Quality
Printability:
Designed to be printable for workshop use.
Binding Type
Binding Type:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, V-twin (90-degree)
Displacement:
1,700 cc (103.6 cu. in.)
Bore X Stroke:
102.0 x 104.0 mm
Valve Train:
SOHC, 4 valves per cylinder, pushrod-actuated
Performance
Horsepower:
Approx. 73 hp @ 5,000 rpm (claimed)
Torque:
Approx. 108 lb-ft @ 3,500 rpm (claimed)
Fuel System
Fuel Delivery:
Digital Fuel Injection (DFI) with dual 40mm throttle bodies
Fuel Type:
Unleaded gasoline, 91 octane (or higher recommended)
Cooling System
Cooling Method:
Liquid cooling with fan
Lubrication System
Oil Type Specification:
SAE 10W-40 API SG or SH, JASO MA certified
Oil Capacity:
4.4 US qt. (4.2 L) with filter change
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Optional
Clutch Type:
Wet, multi-disc
Features
Final Drive:
Belt drive
Transmission Fluid Specification:
Kawasaki Motorcycle Gear Oil or equivalent (refer to manual for exact specification and capacity)
📐 Dimensions
Exterior
Length:
2,510 mm (98.8 in.)
Width:
970 mm (38.2 in.)
Height:
1,540 mm (60.6 in.)
Wheelbase:
1,635 mm (64.4 in.)
Weights
Curb Weight:
Approx. 373 kg (822.5 lbs)
Fuel Tank Capacity:
20 L (5.3 US gal.)
🛡️ Safety Features
Ratings
ABS Availability:
Available (Voyager ABS model)
Active Features
Braking System:
Dual 300mm disc front brakes with 4-piston calipers, Single 300mm disc rear brake with 2-piston caliper.
Passive Features
Lighting:
Halogen headlight, LED taillight, turn signals.
💡 Technology Features
Infotainment
Audio System:
Integrated audio system with handlebar-mounted controls, AM/FM radio, CD player, and iPod/MP3 input (functionality may vary by specific model/package).
Driver Assistance
ABS:
Anti-lock Braking System (ABS) available on select models for enhanced braking control.
Connectivity
Cruise Control:
Electronic cruise control system for rider comfort on long journeys.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Change:
Every 4,000 miles (6,000 km) or 6 months, whichever comes first.
Air Filter Inspection And Cleaning:
Every 4,000 miles (6,000 km)
Spark Plug Replacement:
Every 7,500 miles (12,000 km)
Valve Clearance Check:
Every 15,000 miles (24,000 km)
Fluid Specifications
Coolant Type:
Kawasaki All Season Motorcycle Coolant or equivalent (50/50 mix with distilled water)
Brake Fluid Type:
DOT 4 (refer to manual for specific caliper/master cylinder requirements)
Known Issues
Common Wear Items:
Brake pads, tires, clutch plates, belt drive components (inspect for wear/tension).
Potential Electrical Concerns:
While generally reliable, potential issues may include regulator/rectifier failures or battery charging system concerns, especially after prolonged use.
📚 Vehicle History
Brand Heritage
Kawasaki Motorcycles:
Kawasaki Heavy Industries, Ltd. has a long and rich history in motorcycle manufacturing, known for innovation and performance across various segments.
Model Evolution
Vulcan Lineage:
The Vulcan nameplate has been used for Kawasaki's cruiser line since the late 1980s, evolving through various displacements and styles. The 1700 series represents a significant step up in size and touring capability.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
The Vulcan 1700 Voyager was generally well-received by motorcycle publications for its comfort, power, and value proposition within the touring segment.
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