Front suspension and handlebars of motorcycle Kawasaki VN900 Vulcan (2006-2024)

Front suspension exploded view
No. Fastener Torque Remarks N·m kgf·m ft·lb 1 Upper Front Fork Clamp Bolts 20 2.0 15 2 Lower Front Fork Clamp Bolts 34 3.5 25 3 Front Fork Bottom Allen Bolts 20 2.0 15 L 4 Front Fork Upper Cover Stopper Bolts 4.2 0.43 37 in·lb G: Apply grease. L:...

Suspension special tools
Inside Circlip Pliers: 57001-143 Fork Outer Tube Weight: 57001-1218 Fork Cylinder Holder Handle: 57001-183 Front Fork Oil Seal Driver: 57001-1219 Fork Cylinder Holder Adapter: 57001-1057 Jack: 57001-1238 Bearing Driver Set: 57001-1129 Fork Oil Level...

Front fork (each fork leg) — removal and installation
Front fork removal (each fork leg) Loosen the front axle nut (see Front wheel removal in the Wheels/Tires chapter). Using the jack [A] under the frame pipes, and a commercially available jack [B] under the engine, lift the front wheel off the ground...

Front fork oil change
Remove the front fork (see Front fork removal (each fork leg) ). Remove the top cap. Hold the outer tube vertically in a vise. Push the top plug [A] down to remove the plug retaining ring [B], and then remove the plug. Remove: Fork Spring [A]. Pour...

Front fork disassembly
Remove the front fork (see Front fork removal (each fork leg) ). Drain the fork oil (see Front fork oil change ). Hold the front fork horizontally in a vise [A]. Stop the cylinder unit [B] from turning by using the special tools. Unscrew the Allen...

Front fork assembly
Replace the following parts with new one. Dust Seal [A] Retaining Ring [B] Oil Seal [C] Inner Guide Bushing [D] Outer Guide Bushing [E] Bottom Allen Bolt Gasket [F] Install the following parts onto the inner tube. Dust Seal Retaining Ring Oil Seal...

Inner tube inspection
Visually inspect the inner tube, and repair any damage. Nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. ★ If the damage is not repairable, replace the inner tube....

Steering exploded view
No. Fastener Torque Remarks N·m kgf·m ft·lb 1 Handlebar Clamp Bolts 34 3.5 25 O, S 2 Handlebar Holder Nuts 34 3.5 25 3 Steering Stem Head Nut 49 5.0 36 4 Upper Front Fork Clamp Bolts 20 2.0 15 5 Steering Stem Nut 4.9 0.50 43 in·lb 6 Lower Front Fork...

Steering special tools
Bearing Puller: 57001-135 Steering Stem Nut Wrench: 57001-1100 Steering Stem Bearing Driver: 57001-137 Head Pipe Outer Race Driver, ∅46.5: 57001-1106 Steering Stem Bearing Driver Adapter, ∅34.5: 57001-1074 Head Pipe Outer Race Remover, ID 37 mm:...

Handlebar — removal and installation
Handlebar removal Remove: Clutch Lever Assembly [A] Left Handlebar Switch Housing [B] Remove: Front Master Cylinder [A] (see Front master cylinder removal in the Brakes chapter) Right Handlebar Switch Housing [B] Throttle Grip [C] Remove: Caps [A]...

Steering stem — removal and installation
Steering stem removal Remove the front wheel (see Front wheel removal in the Wheels/Tires chapter). Caution! Be sure to put the rear wheel on the ground when removing the steering, or the motorcycle may fall over. The motorcycle could be damaged....

Steering stem bearing — removal and installation
Stem bearing removal Remove the steering stem (see Steering stem removal ). Drive out the bearing outer races from the head pipe. Special Tool - Head Pipe Outer Race Remover, ID 37 mm [A]: 57001-1107 Note. Of either steering stem bearing is damaged,...