Frame and attachments of motorcycle Kawasaki VN900 Vulcan (2006-2024)

Frame exploded view
No. Fastener Torque Remarks N·m kgf·m ft·lb 1 Downtube Bolts 44 4.5 32 2 Footboard Bracket Bolts 34 3.5 25 3 Sidestand Mounting Nut 44 4.5 32 4 Lower Muffler Bracket Bolts 34 3.5 25 5 Upper Muffler Bracket Bolts 34 3.5 25 6 Sidestand Mounting Bolt...

Seats — removal and installation
Seat removal Insert the ignition switch key [A] into the seat lock, turning the key clockwise, pulling up on the rear of the seat [B], and pulling the seat backward. Seat installation Slip the seat hook [A] under the brace [B] on the fuel tank...

Left side cover — removal and installation
Left side cover removal Remove: Seat (see Seat removal ) Screw [A] Pull [A] the left side cover evenly, and remove it. Left side cover installation Put the front stoppers [A] into the grommets [B] first, then put the rear stopper [C] into the...

Right side cover — removal and installation
Right side cover removal Remove: Seat (see Seat removal ) Screw [A] Caution! Be careful not to scratch the right side cover surface with the upper exhaust pipe cover [A] during removal or installation. Cover the rear exhaust pipe with a shop towel...

Fenders — removal and installation
Front fender removal Caution! Be careful not to scratch the painted surface during removal or installation. Remove the mounting bolts [A] and washers on both sides to separate the fender from the front fork. Move the fender forwards with the wheel...

Battery case removal
Remove: Seat (see Seat removal ) Battery (see Battery removal in the Electrical System chapter) ECU [A] (see ECU removal in the Fuel System (DFI) chapter) Relay Box (see Relay box removal in the Electrical System chapter) Fuse Box (see Electrical...

Tool box removal
Clear the seat lock cable [A] from the hook [B]. Remove: Seat (see Seat removal ) Screws [C] Tool Box [D]

Footboard — removal and installation
Footboard removal/installation Left side Remove: Shift Pedal Clamp Bolt [A] Footboard Bracket Bolts [B] Left Footboard Assembly [C] Install the shift pedal to the front shift lever so that the punch mark [A] on the pedal align to the punch mark [B]...

Footboard — disassembly and assembly
Footboard disassembly Remove the each footboard (see Footboard removal/installation ). Remove: Spring [A] Circlip [B] Pin [C] Footboard assembly Replace the circlip [A] with a new one. Install: Left Front Footboard Damper [B] Left Front Footboard...

Sidestand — removal and installation
Sidestand removal Raise the rear wheel [A] off the ground, using the jack [B]. Special Tool - Jack: 57001-1238 Remove the alternator outer cover (see Alternator outer cover removal in the Electrical System chapter). Disconnect the sidestand switch...

Windshield (VN900D) — removal and installation
Windshield height adjustment The windshield [A] can be adjusted within 50 mm (2.0 in.) in height to suit the rider's preference. Loosen the upper and lower bolts [B] on both sides and slide the windshield up or down. Check to see that the position...

Saddlebags (VN900D) — removal and installation
Saddlebag removal Open the lid. Remove: Bolt [A] Nuts [B] Saddlebag Saddlebag installation Be sure that the washers [A] are in place. Install: Saddlebag Tighten: Nuts [A] Bolt [B]

Rear view mirrors — removal and installation
Rear view mirror removal (other than Europe models) Loosen the locknut [A]. Turn the rear view mirror stay [B] counterclockwise to remove the rear view mirror from the holder [C]. Rear view mirror removal (Europe models) Loosen the lower hexagonal...

Downtube — removal and installation
Downtube removal Raise the rear wheel [A] off the ground, using the jack [B]. Special Tool - Jack: 57001-1238 Remove: Fuel Tank (see Fuel tank removal in the Fuel System (DFI) chapter) Disconnect the rear brake light switch connector [A]. Remove:...

Back rest (VN900D) — removal and installation
Back rest removal/installation Remove: Bolts (Both Sides) [A] Back Rest Assy [B] Remove: Bolts [A] Plate [B] Back Rest Pad [C] Install: Back Rest Side Stays (Both Sides) [A] Saddlebag Brackets (Both Sides) [B] Tighten: Nuts (Both Sides) [C] Install:...

Frame inspection
Visually inspect the frame [A] for cracks, dents, bending, or warp. ★ If there is any damage to the frame, replace it. Warning! A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace...

Cable, wire and hose routing
1. Right Switch Housing Harness; 2. Left Switch Housing Harness; 3. Clutch Cable; 4. Clamp the right switch housing harness; 5. Through the clutch cable and left switch housing harness; 6. Run the clutch cable through the brake hose front side; 7....