User manual KAWASAKI VULCAN900 CLASSIC SERVICE MANUAL

[. . . ] VULCAN900 CLASSIC VULCAN900 CLASSIC LT VN900 CLASSIC Motorcycle Service Manual Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System This quick reference guide will assist you in locating a desired topic or procedure. ·Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. ·Refer to the sectional table of contents for the exact pages to locate the specific topic required. 1j 2j 3j 4j 5j 6j 7j 8j 9j 10 j 11 j 12 j 13 j 14 j 15 j 16 j Appendix 17 j VULCAN900 CLASSIC VULCAN900 CLASSIC LT VN900 CLASSIC Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd. , Japan. [. . . ] Original Seating Surface [B] Remove all pittings of flaws from 45° ground surface. After grinding with 45° cutter, apply thin coat of machin- NOTE ist's dye to seating surface. This makes seating surface distinct and 32° and 60° grinding operation easier. When the valve guide is replaced, be sure to grind with 45° cutter for centering and good contact. If the outside diameter of the seating surface is too large, make the 32° grind described below. If the outside diameter [A] of the seating surface is within the specified range, measure the seat width as described below. To make the 32° grind, fit a 32° cutter into the holder, and slide it into the valve guide. Check the seat after each turn. · CAUTION The 32° cutter removes material very quickly. Check the seat outside diameter frequently to prevent overgrinding. After making the 32° grind, return to the seat O. D. To measure the seat width, use a vernier caliper to measure the width of the 45° angle portion of the seat at several places around the seat. If the seat width is too narrow, repeat the 45° grind until the seat is slightly too wide, and then return to the seat O. D. measurement step above. If the seat width is too wide, make the 60° [A] grind described below. If the seat width is within the specified range, lap the valve to the seat as described below. Grind the seat at a 60° angle until the seat width is within the specified range. To make the 60° grind, fit 60° cutter into the holder, and slide it into the valve guide. After making the 60° grind, return to the seat width measurement step above. Correct Width [B] · ENGINE TOP END 5-31 Valves the valve to the the seat · Lap within the rangesseat, onceabove. are specified Put a little coarse grinding compound on the face of the valve in a number of places around the valve head. Spin the valve against the seat until the grinding compound produces a smooth, matched surface on both the seat and the valve. Lapper [A] Valve Seat [B] Valve [C] The seating area should be marked about in the middle of the valve face. If the seat area is not in the right place on the valve, check to be sure the valve is the correct part. When the engine is assembled, be sure to adjust the valve clearance (see Valve Clearance Adjustment in the Periodic Maintenance chapter). · · · 5-32 ENGINE TOP END Valves ENGINE TOP END 5-33 Cylinders, Pistons Cylinder Removal · Drain the coolant (see Coolant Change in the Periodic Maintenance chapter). [. . . ] Air Switching Valve Hose 17-14 APPENDIX Cable, Wire and Hose Routing APPENDIX 17-15 Cable, Wire and Hose Routing 1. Run the starter motor lead through the engine bracket clamp. 17-16 APPENDIX Cable, Wire and Hose Routing APPENDIX 17-17 Cable, Wire and Hose Routing 1. Connect the battery negative (­) lead connector to the main harness. Sidestand Switch Lead 17-18 APPENDIX Cable, Wire and Hose Routing APPENDIX 17-19 Cable, Wire and Hose Routing 1. [. . . ]