Brake system of motorcycle Kawasaki VN900 Vulcan (2006-2024)

Brakes exploded view
No. Fastener Torque Remarks N·m kgf·m ft·lb 1 Brake Lever Pivot Bolt 1.0 0.10 8.8 in·lb Si 2 Brake Lever Pivot Bolt Locknut 5.9 0.60 52 in·lb 3 Front Brake Disc Bolts 27 2.8 20 L 4 Front Brake Hose Banjo Bolts 25 2.5 18 5 Front Brake Light Switch...

Brakes specifications and special tool
Specifications Item Standard Service Limit Brake Lever, Brake Pedal Brake Lever Position No.1 5-way adjustable Brake Lever Free Play Non-adjustable — Pedal Free Play Non-adjustable — Pedal Position About 130 mm (5.12 in.) (height from pedal top to...

Brake lever, brake pedal — adjustment
Brake lever position adjustment The brake lever adjuster has 5 positions so that the brake lever position can be adjusted to suit the operator's hand. Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on...

Brake pedal — removal and installation
Brake pedal removal Remove: Brake Fluid Reservoir (see Brake pedal position adjustment ) Brake Pedal Clamp Bolt [A] Brake Pedal [B] Loosen: Rear Master Cylinder Mounting Bolts [C] Remove: Right Footboard Bolts [D] Rear Master Cylinder Mounting Bolts...

Calipers — removal and installation
Front caliper removal Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. Unscrew the caliper mounting bolts [B]. Take off the caliper [C] from the disc. Unscrew the banjo bolt, and remove the brake hose from the caliper....

Calipers — damage repair
Caliper fluid seal damage The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may...

Front brake pad — removal and installation
Front brake pad removal Remove the front caliper with the hose installed (see Front caliper removal ). Remove: Snap Pin [A] Pad Pin [B] Remove the jaw side pad [A], and then remove the piston side pad [B]. Jaw [C] Front brake pad installation Before...

Rear brake pad — removal and installation
Rear brake pad removal Remove the rear caliper with the hose installed (see Rear caliper removal ). Remove: Snap Pin [A] Pad Pin [B] Remove the jaw side pad [A], and then remove the piston side pad [B]. Jaw [C] Rear brake pad installation Before...

Front master cylinder — removal and installation
Front master cylinder removal Disconnect the front brake light switch connectors [A]. Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder (see Brake hose replacement in the Periodic Maintenance chapter). Remove the clamp...

Rear master cylinder — removal and installation
Rear master cylinder removal Remove the brake fluid reservoir (see Brake pedal position adjustment ). Unscrew the brake hose banjo bolt [A] on the master cylinder. Loosen the rear master cylinder mounting bolts [B]. Unscrew the footboard bracket...

Master cylinder inspection
Disassemble the front and rear master cylinders (see Master cylinder rubber parts replacement in the Periodic Maintenance chapter). Caution! Do not remove the secondary cup from the piston since removal will damage it. Check that there are no...

Brake disc — removal and installation
Brake disc removal Remove the wheel (see Wheels (rims) section in the Wheels/Tires chapter). Unscrew the mounting bolts [A], and take off the disc. Brake disc installation Install the brake disc [A] on the wheel so that the marked side [B] faces...

Brake disc wear
Measure the thickness of each disc [A] at the point where it has worn the most. Measuring Area [B] ★ Replace the disc if the sliding surface has worn past the service limit. Brake discs thickness: Standard: Front 4.8-5.2 mm (0.19-0.20 in.) Rear...

Brake disc warp
Jack up the motorcycle so that the wheel is off the ground (see Front wheel removal in the Wheels/Tires chapter) (see Rear wheel removal in the Wheels/Tires chapter). OFor front disc inspection, turn the handlebar fully to one side. Set up a dial...

Brake line bleeding
Brake fluid level inspection Refer to the Brake fluid level inspection in the Periodic Maintenance chapter. Brake fluid change Refer to the Brake fluid change in the Periodic Maintenance chapter. Brake line bleeding The brake fluid has a very low...