User manual KAWASAKI VULCAN 800 SERVICE MANUAL

[. . . ] No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication. [. . . ] If the oil level is too low, add the correct amount of oil through the oil filler opening. Use the same type and make of oil that is already in the engine. If the engine oil type and make are unknown, use any brand of the specified oil to top off the level in preference to running the engine with the oil level low. Then at your earliest convenience, change the oil completely. Engine Oil Change nance Chapter. NOTE Refer to the Engine Oil Change in the Periodic MainteOil Filter Replacement tenance Chapter. Refer to the Oil Filter Replacement in the Periodic Main- ENGINE LUBRICATION SYSTEM 7-9 Oil Pump and Oil Line Oil Pump Removal · Remove the engine (see Engine Removal/Installation chapter). · Remove the oil pump mounting bolts [A], and take off the pump [B] out of the right crankcase. · Remove:[A] Circlip Washer [B] Pump Shaft [C] Pump Gear [D] Oil Pump Installation oil shaft tang · Note the position of the thatpumptang fits into[A] and turn the pump gear shaft so the the slot [B] · · · of the oil pump gear. Tighten: Torque - Oil Pump Mounting Bolts: 11 N·m (1. 1 kgf·m, 97 in·lb) the · Check that right oil pump gear turns smoothly in the left side of the crankcase. Apply a non-permanent locking agent to the threads of · the relief valve and install it. Torque - Relief Valve: 15 N·m (1. 5 kgf·m, 11 ft·lb) Oil Hose Removal · Remove the engine (see Engine Removal/Installation chapter). · Remove:Case Cover (see Engine Top End chapter) Rocker · Oil Hose Flange Bolts [A] on Front and Rear Rocker Cases Oil Hose Banjo Bolt [B] on Right Crankcase behind Rear Cylinder Remove the front oil hose [C] and the rear oil hose [D]. Front [E] 7-10 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line Oil Hose Installation the · Run the front oil hose over first. rear oil hose as shown. Fit the clamp [D] · rocker case and the Torque - Oil Hose Flange Bolts: 9. 8 N·m (1. 0 kgf·m, 87 in·lb) · Install each bottom end of the oilashoses on the right crankcase behind the rear cylinder shown. Front Oil Hose [A] Rear Oil Hose [B] Front [C] Face the paint marks [D] rearward. Replace the copper washers on each side of the banjo bolt with new ones. · · Install the removed ports. Torque - Oil Hose Banjo Bolt [E]: 9. 8 N·m (1. 0 kgf·m, 87 in·lb) Inside Oil Pipe Removal · Split the crankcase (see Crankshaft/Transmission chapter). Also, replace the oil filter. Oil Pressure Standard: 340 440 kPa (3. 5 4. 5 kgf/cm², 50 64 psi) @2 000 r/min (rpm), oil temp. Remove · WARNING Take care against burns from hot engine oil that will drain through the oil passage when the plug is removed. apply silicone · When installing the oilofpressure switch, tighten it to the sealant to the threads the switch, and specified torque. · Apply greaseoil pressure switch switchand slide back the Connect the lead · rubber boot to the original position. Torque - Oil Pressure Switch: 15 N·m (1. 5 kgf·m, 11 ft·lb) 7-16 ENGINE LUBRICATION SYSTEM Oil Pressure Relief Valve Inspection · Split the crankcase (see Crankshaft/Transmission chapter). · Remove the relief valve [A] from smoothly when pushing Check to see if the valve slides · it in with a wooden or other soft rod, and see if it comes back to its seat by spring pressure. Inspect the valve in its assembled state. NOTE Disassembly and assembly may change the valve performance. If any rough spots are found during above inspection, wash the valve clean with a high-flash point solvent and blow out any foreign particles that may be in the valve with compressed air in a well-ventilated area. Take care that there is no spark or flame anywhere near the working area. Valve [A] Spring [B] If cleaning does not solve the problem, replace the relief valve as an assembly. The relief valve is precision made with no allowance for replacement of individual parts. ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [. . . ] Accessory Lead Connectors (female) 17-36 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-37 Cable, Wire, and Hose Routing F: Front 1. Battery (-) Lead or Engine Ground Lead (to the engine ground terminal) 4. Connectors (in the alternator outer cover for regulator/rectifier, alternator, crankshaft sensors, sidestand switch, neutral/oil pressure switch, and speed sensor) 15. Battery Holder (Install it on the battery and tighten the holder bolts securely. ) 24. [. . . ]