Kawasaki Vulcan 700, 750, 800 Repair & Service Manual 1985-2004

SKU: HYM2457-04

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Kawasaki Vulcan 700, 750, 800 Repair Manual 1985-2004
Kawasaki Vulcan 700, 750, 800 Repair Manual 1985-2004
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Item Description

This Haynes 2457 repair manual covers 1985-2004 Kawasaki Vulcan motorcycles, including:

  • Kawasaki Vulcan 700, 1985
  • Kawasaki Vulcan 750, 1985-2004
  • Kawasaki Vulcan 800, 1995-2004
  • Kawasaki Vulcan 800 Classic, 1996-2002
  • Kawasaki Vulcan 800 Drifter, 1999-2004

Book Excerpt: 1985-2004 Kawasaki Vulcan, Classic, Drifter Repair Manual




  1. If the engine is overheating and the cooling fan isn't coming on, first check the fuses (see Chapter 9). If the fuse is blown, check the fan circuit for a short to ground (see the Wiring diagrams at the end of this book).

    If the fuses are all good, disconnect the fan electrical connector (see illustration 11.a or 1.1b). Using two jumper wires, apply battery voltage to the terminals in the fan motor side of the electrical connector. If the fan doesn't work, replace the motor.

  2. If the fan does come on, the problem lies in the thermostatic fan switch, the junction block, or the wiring that connects the components. Remove the jumper wires and reconnect the electrical connector to the fan.
  3. If you're working on a Vulcan 700/750 model (with a single-wire fan switch harness), disconnect the electrical connector from the fan switch, attach a jumper wire to the harness side of the connector and ground the other end of the jumper wire.

    If the fan comes on, the circuit to the motor is good, and the thermostatic fan switch is defective.

  4. If you're working on a Vulcan 800 model (with a double-wire fan switch connector), disconnect the connector.

    Connect the terminals in the harness side of the connector together with a jumper wire. If the fan comes on, the circuit to the motor is good and the switch is defective.

  5. If you're working on Vulcan 700/750 model and the fan still doesn't work, trace the fan relay (located under the seat on the junction box - use its wire colors for identification) and place your hand on it.

    Repeatedly touch the jumper wire to ground as detailed in Step 3 - if you feel and hear a clicking inside the relay, the relay is good and the fault must lie in the wiring from the relay to the fan motor.

  1. If the master cylinder is leaking fluid, or if the lever does not produce a firm feel when the brake is applied, and bleeding the brakes does not help, master cylinder overhaul is recommended.

    Before disassembling the master cylinder, read through the entire procedure and make sure that you have the correct rebuilt kit.

    Also, you will need some new, clean brake fluid of the recommended type, some clean rags and internal snap-ring pliers.

    Caution: To prevent damage to the paint from spilled brake fluid, always cover the fuel tank when working on the master cylinder.

  2. Caution: Disassembly, overhaul and reassembly of the brake master cylinder must be done in a spotlessly clean work area to avoid contamination and possible failure of the brake hydraulic system components.

Subject: 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Kawasaki Vulcan 700, 750, 800 service, maintenance, repair. ISBN-10: 1620921472 | ISBN-13: 9781620921470 | Haynes 2457

  • Publisher: Haynes Manuals
  • Pages: 256 - Hundreds of b&w photos and illustrations
  • Binding: Softcover - 8.5 x 11 inches
  • ISBN: 978-1-62092-147-0
  • Years: 1985 - 2004
Table of Contents
  • Identification numbers
  • Buying parts
Daily (pre-ride) checks
  • Engine/transmission oil level check
  • Brake fluid level checks
  • Suspension, steering and final drive checks
  • Tire checks
MAINTENANCE Routine maintenance and servicing
  • Specifications
  • Maintenance schedule
  • Component locations
  • Maintenance procedures
REPAIRS and OVERHAUL Engine, transmission and associated systems
  • Engine, clutch and transmission
  • Cooling system
  • Fuel and exhaust systems
  • Ignition system
Chassis components
  • Steering
  • Suspension
  • Final drive
  • Wheels
  • Brakes
  • Tires
  • Frame and bodywork
Electrical system | Wiring diagrams REFERENCE
  • Tools and workshop tips
  • Storage
  • Troubleshooting
Questions & Answers about Kawasaki Vulcan 700, 750, 800 Repair Manual 1985-2004

Questions & Answers about Kawasaki Vulcan 700, 750, 800 Repair Manual 1985-2004

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Customer Reviews


Matt HAugust 15, 2019
Road Ready
Hopefully this helps me get on the road fully restoring my 94' 750 vtwin
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Kawasaki Vulcan 700, 750, 800 Repair & Service Manual 1985-2004
Free Shipping (US48)
In Stock