Elements of transmission motorcycle Kawasaki VN900 Vulcan (2006-2024)

Clutch exploded view and specifications
No. Fastener Torque Remarks N·m kgf·m ft·lb 1 Right Engine Cover Bolts 98 1.0 87 in·lb L (1) 2 Clutch Hub Nut 130 13.2 95.9 MO 3 Clutch Spring Bolts 9.8 1.0 87 in·lb CL: Apply cable lubricate. EO: Apply engine oil. G: Apply grease. L: Apply a...

Clutch lever and cable
Clutch lever free play inspection Refer to the Clutch operation inspection in the Periodic Maintenance chapter. Clutch lever free play adjustment Refer to the Clutch operation inspection in the Periodic Maintenance chapter. Clutch cable removal...

Right engine cover
Right engine cover removal Drain: Engine Oil (see Engine oil change in the Periodic Maintenance chapter) Coolant (see Coolant change in the Periodic Maintenance chapter) Remove: Brake Pedal (see Brake pedal removal in the Brakes chapter) Right...

Clutch — removal and installation
Clutch removal Remove: Right Engine Cover (see Right engine cover removal ) Clutch Spring Bolts [A] Clutch Springs Clutch Spring Plate [B] (with thrust bearing and pusher [C]) Remove: Friction Plates, Steel Plates Clutch Hub Nut [A] Holding the...

Crankshaft/transmission exploded view
No. Fastener Torque Remarks N·m kgf·m ft·lb 1 Crankcase Bolts (M6) 9.8 1.0 87 in·lb S 2 Crankcase Bolts (M10) 39 4.0 29 S 3 Connecting Rod Big End Bolts 46 4.7 34 MO 4 Primary Gear Bolt 98 10 72 MO 5 Balancer Gear Bolt 69 7.0 51 6 Starter Motor...

Crankshaft/transmission specifications
Item Standard Service Limit Crankshaft, Connecting Rods Connecting Rod Big End Side Clearance 0.08 - 0.3 mm (0.003 - 0.01 in.) 0.5 mm (0.02 in.) Connecting Rod Big End Bearing Insert/Crankpin Clearance 0.026 - 0.054 mm (0.0010 - 0.0021 in.) 0.09 mm...

Crankshaft/transmission special tools and sealants
Outside Circlip Pliers: 57001-144 Rotor Holder: 57001-1674 Bearing Driver Set: 57001-1129 Kawasaki Bond (Silicone Sealant): 92104-0004 Grip: 57001-1591 Kawasaki Bond (Liquid Gasket - Black): 92104-1064

Crankcase splitting
Remove the engine (see Engine removal in the Engine removal/installation chapter). Set the engine on a clean surface and hold the engine steady while parts are being removed. Remove: Starter Motor (see Starter motor removal in the Electrical System...

Crankcase assembly
Note. The right and left crankcase halves are machined at the factory in the assembled state, so the crankcase halves must be replaced as a set. With a high-flash point solvent, clean off the mating surfaces of the crankcases halves and wipe dry....

Crankshaft/connecting rods
Crankshaft removal Split the crankcase (see Crankcase splitting ). Remove the crankshaft. Crankshaft installation Insert the crankshaft tapered end in to the left crankcase [A]. Install the left connecting rod [B] into the rear cylinder opening [C],...

Balancer, starter motor clutch
Left balancer removal Remove the alternator cover (see Alternator cover removal in the Electrical System chapter). Wipe oil off the outer circumference of the alternator rotor. Hold the alternator rotor steady with the rotor holder [A], and remove...

Torque limiter — removal and inspection
Torque limiter removal Remove: Right Engine Cover (see Right engine cover removal in the Clutch chapter) Washer [A] Starter Motor Clutch Gear [B] (see Right balancer and starter motor clutch removal ) Torque Limiter [C] Caution! Do not disassemble...

Primary gear — removal and inspection
Primary gear removal Remove the alternator cover (see Alternator cover removal in the Electrical System chapter). Wipe oil off the outer circumference of the alternator rotor. Hold the alternator rotor steady with the rotor holder [A]. Special...

Shift pedal — removal and installation
Shift pedal removal Remove: Shift Pedal Clamp Bolt [A] Remove: Footboard Bracket Bolts [A] Footboard [B] together with the Shift Pedal [C] Separate the shift pedal from the footboard. Shift pedal installation Apply grease to the shift pedal shaft....

External shift mechanism — removal and installation
External shift mechanism removal Remove: Shift Pedal (see Shift pedal removal ) Alternator Outer Cover (see Alternator outer cover removal in the Electrical System chapter) Engine Pulley (see Engine pulley removal in the Final Drive chapter) Pry...

Transmission shaft and shift fork
Transmission shaft and shift fork removal Split the crankcase (see Crankcase splitting ). Remove: Shift Rod [A] Shift Forks [B] Take out the drive shaft [C] and output shaft [D] as a set. Transmission shaft and shift fork installation Apply engine...

Shift drum — removal and installation
Shift drum removal Remove: Transmission Shafts (see Transmission shaft and shift fork removal ) Bolts [A] Bearing Stopper [B] While aligning the shift drum cam with the left crankcase hole, pull out the shift drum [C]. Shift drum installation While...

Shift fork/gear groove/gear dog
Shift fork bending Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power. 90° [A] Shift fork/gear groove wear Measure the...

Bearing and oil seal installation
When installing a bearing other than the following parts, press it in with the marked side facing out. Special Tool - Bearing Driver Set: 57001-1129 Right crankcase Press the water pump shaft bearing and oil seal as shown. [A] Oil Seal [B] Marked...

Final drive exploded view
No. Fastener Torque Remarks N·m kgf·m ft·lb 1 Rear Pulley Mounting Nuts 59 6.0 44 2 Rear Pulley Plate Bolts 6.9 0.70 61 in·lb L 3 Engine Pulley Mounting Nut 127 13.0 93.7 M 4 Engine Pulley Plate Bolts 9.8 1.0 87 in·lb 5 Engine Pulley Cover Bolts 9.8...

Final drive specifications and special tools
Specifications Item Standard Service Limit Drive Belt Make GATES, 153T — Belt Deflection (45 N, 4.6 kgf, 10 lb force) 1.5 - 4.0 mm (0.059 - 0.16 in.) — (When installing new belt or engine is remounted) 1.5 mm (0.059 in.) — Special tools Inside...

Belt handling precautions
The drive belt must be checked, and adjusted in accordance with the Periodic Maintenance Chart for safety and to prevent excessive wear. If the belt becomes badly worn or maladjusted-either too loose or too tight-the belt could jump off the pulley...

Drive belt — removal and installation
Drive belt wear inspection Refer to the Belt wear inspection in the Periodic Maintenance chapter. Drive belt deflection inspection Refer to the Belt deflection inspection in the Periodic Maintenance chapter. Drive belt deflection adjustment Refer to...

Pulley and coupling
Engine pulley cover removal Remove: Alternator Outer Cover (see Alternator outer cover removal in the Electrical System chapter) Bolt [A] Clamp [B] Bolts [C] Engine Pully Cover [D] Engine Pulley Cover Installation Install: Drive Belt Guide [A]...

Belt adjuster — removal and installation
Belt adjuster removal Remove the left and right belt adjuster locknuts [A] and belt adjuster nuts [B]. Remove the belt adjuster [C] from the swingarm. Belt adjuster installation Apply 2-stroke oil to the inside of the belt adjuster sliding surface....