Motorcycle engine repair Kawasaki VN900 Vulcan (2006-2024)

Engine top end exploded view
No. Fastener Torque Remarks N·m kgf·m ft·lb 1 Cylinder Head nuts(M10)(First) 20 2.0 15 S, MO Cylinder Head nuts(M10)(Final) 49 5.0 36 S, MO 2 Cylinder Head nuts(M8) 25 2.5 18 S 3 Camshaft Cap Bolts 25 2.5 18 4 Cylinder Head Cover Bolts 12 1.2 106...

Engine top end specifications
Item Standard Service Limit Camshafts Cam Height: Exhaust 35.030 - 35.144 mm (1.3791 - 1.3836 in.) 34.93 mm (1.375 in.) Inlet 35.302 - 35.416 mm (1.3898 - 1.3943 in.) 35.20 mm (1.386 in.) Camshaft Journal, Camshaft 0.028 - 0.071 mm (0.0011 - 0.0028...

Engine top end special tools
Compression Gauge, 20 kgf/cm²: 57001-221 Valve Seat Cutter, 60° - ∅30: 57001-1123 Valve Spring Compressor Assembly: 57001-241 Valve Seat Cutter Holder Bar: 57001-1128 Piston Pin Puller Assembly: 57001-910 Valve Seat Cutter, 45° - ∅30: 57001-1187...

Clean air system
Air suction valve removal Remove: Cylinder Head Covers (see Cylinder head cover removal ) Air Suction Valves [A] Air suction valve installation Install each air suction valve so that stopper side [A] of the reed faces downward. Air suction valve...

Cylinder head cover
Cylinder head cover removal Remove: Seat (see Seat removal in the Frame chapter) Fuel Tank (see Fuel tank removal in the Fuel System (DFI) chapter) Slide [A] the air switching valve [B] forward to clear the clamp. Remove: Bolt [A] Clamp [B] Remove:...

Camshaft chain tensioner
Camshaft chain tensioner removal Remove: Engine (see Engine removal /Installation chapter) Camshaft (see Camshaft removal ) Cylinder Head (see Cylinder head removal ) Remove the camshaft chain tensioner body from the cylinder. Camshaft chain...

Camshaft removal
Remove: Cylinder Head Cover (see Cylinder head cover removal ) Ignition Coil Cover (For Front Cylinder) (see Ignition coil removal in the Electrical System chapter) Tensioner Cap Bolt [A], Washer [B] and Spring Caution! Do not turn over the...

Camshaft installation
Apply engine oil to all cam parts and journals. Note. The front and rear camshafts are different. The rear camshaft [A] has a groove [B]. Remove: Alternator Outer Cover (see Alternator outer cover removal in the Electrical System chapter) Bolts [A]...

Camshaft/camshaft cap wear
Cut strips of plastigage to journal width. Place a strip on each journal parallel to the camshaft installed in the correct position. Measure each clearance between the camshaft and the rocker case using plastigage. Note. Do not turn the camshaft...

Camshaft runout/cam wear
Camshaft runout Remove the camshaft (see Camshaft removal ). Set the camshaft in a camshaft alignment jig or on V blocks. Measure runout with a dial gauge at the specified place as shown. ★ If the runout exceeds the service limit, replace the shaft....

Camshaft chain removal
Front camshaft chain Remove: Front Camshaft (see Camshaft removal ) Alternator Rotor (see Alternator rotor removal in the Electrical System chapter) Bolts [A] Rear Chain Guide [B] Bolt [C] and Washer [D] Front Chain Guide [E] Disengage the camshaft...

Camshaft and sprocket assembly
Clean the sprocket bolt [A] and threads of the camshaft. Be sure to install the pin [B]. Apply a non-permanent locking agent to the threads of the camshaft sprocket bolt, and tighten it. The sprockets are identical. Torque - Camshaft Sprocket Bolt:...

Rocker shaft, rocker arm
Rocker shaft, rocker arm removal Remove: Cylinder Head Cover (see Cylinder head cover removal ) Camshaft Cap (see Camshaft removal ) Rocker Shafts [A] Rocker Arms [B] and Springs [C] Rocker shaft, rocker arm installation Apply molybdenum disulfide...

Cylinder compression measurement
Note. Use the battery which is fully charged. Warm up the engine thoroughly. Stop the engine. Remove: Seat (see Seat removal in the Frame chapter) Fuel Tank (see Fuel tank removal in the Fuel System (DFI) chapter) Spark Plugs Special Tool - Spark...

Cylinder head — removal and installation
Cylinder head removal Remove: Engine (see Engine removal in the Engine Removal/Installation chapter) Camshaft (see Camshaft removal ) Remove the cylinder head nuts following sequence [1-6]. Remove: Cylinder Head Cylinder head installation Note. The...

Valves — removal and installation
Valve clearance inspection Refer to the Valve clearance inspection in the Periodic Maintenance chapter. Valve clearance adjustment Refer to the Valve clearance adjustment in the Periodic Maintenance chapter. Valve removal Remove the cylinder head...

Valve guide — removal and installation
Valve guide removal Remove: Valve (see Valve removal ) Stem Oil Seal Spring Seat Heat the area around the valve guide to 120-150°C (248-302°F), and hammer lightly on the valve guide arbor [A] to remove the guide from the top of the head. Caution! Do...

Valve-to-guide clearance measurement (wobble method)
If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below. Insert a new valve [A] into the guide [B] and set a dial gauge against the stem...

Valve seat inspection
Remove the valve (see Valve removal ). Check the valve seating surface [A] between the valve [B] and valve seat [C]. OMeasure the outside diameter [D] of the seating pattern on the valve seat. ★ If the outside diameter is too large or too small,...

Valve seat repair
Repair the valve seat with the valve seat cutters [A]. Special tools: Valve Seat Cutter Holder, ∅5: 57001-1208 [B] Valve Seat Cutter Holder Bar: 57001-1128 [C] [For Inlet Valve Seat] Valve Seat Cutter, 45° - ∅32: 57001-1115 or Valve Seat Cutter, 45°...

Cylinders and pistons — removal and installation
Cylinder removal Drain the coolant (see Coolant change in the Periodic Maintenance chapter). Remove the cylinder head (see Cylinder head removal ). Pull out the front camshaft chain guide [A] and oil pipe [B]. Tap lightly up the cylinder with a...

Muffler — removal and installation
Muffler removal Remove: Clamp Screws (Loosen) [A] Bolt [B] Rear Muffler Cover [C] Remove: Clamp Screws (Loosen) [A] Bolt [B] Front Muffler Cover [C] Remove: Muffler Mounting Nut [A], Collar and Damper Muffler Mounting Bolt [B] Remove: Muffler...

Engine — removal and installation
Exploded view No. Fastener Torque Remarks N·m kgf·m ft·lb 1 Engine Mounting Nuts 44 4.5 32 2 Engine Mounting Bracket Bolts (M10) 44 4.5 32 3 Engine Mounting Bracket Bolts (M8) 25 2.5 18 4 Downtube Mounting Bolts 44 4.5 32 WL: Apply a soap and water...