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VULCAN 2000 VN2000

Quick Reference Guide

VULCAN 2000

VN2000

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

Read OWNER’S MANUAL before operating.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

•Among those acts presumed to constitute tampering are the acts listed below:

Replacement of the original exhaust system or muffler with a component not in compliance

•with Federal regulations.

•Removal of the muffler(s) or any internal portion of the muffler(s).

•Removal of the air box or air box cover.

Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such modifications result in increased noise levels.

Foreword

NOTE

○This note symbol indicates points of particular interest for more efficient and convenient operation.

•Indicatesdone. a procedural step or work to be ○Indicates a procedural sub-step or how to do the work of the procedural step it follows. It

also precedes the text of a NOTE.

Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, disconnect the battery wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (−) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive (+) terminal of the battery then the negative (−) wire to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent

Use a high flush point solvent when cleaning parts. High flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

GENERAL INFORMATION 1-3

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

Gasket, Oring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling

Liquid Gasket, Locking Agent

For applications that require Liquid Gasket or a Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

GENERAL INFORMATION 1-5

Before Servicing

Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new ones. Install the circlip with its sharp edge facing outward and its chamfered side facing inward to prevent the clip from being pushed out of its groove when loaded. Take care not to open the clip excessively when installing to prevent deformation.

Lubrication

It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

1-6 GENERAL INFORMATION

Before Servicing

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from right side).

Electrical Wires

A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

GENERAL INFORMATION 1-7

Model Identification

VN2000-A1 (US, and Canada) Left Side View:

VN2000-A1 (US, and Canada) Right Side View:

1-8 GENERAL INFORMATION

Model Identification

VN2000-A1 (Europe) Left Side View:

VN2000-A1 (Europe) Right Side View:

1-10 GENERAL INFORMATION

General Specifications

GENERAL INFORMATION 1-11

Technical Information – Oxygen Sensor

Overview

Kawasaki has adopted an oxygen sensor [A] for the European and California models in addition to the secondary air injection system and honeycomb catalyst. This helps Kasawaki keep the motorcycle with cleaner exhaust gas and cope with the emission regulations.

The oxygen sensor [A] is mounted above the exhaust manifold [B], whereas the honeycomb catalyst is located inside the silencer in the downstream of the exhaust gas.

The oxygen sensor uses the substance called zirconia (ZrO2). The electromotive force varies depending on the density of the oxygen. The sensor measures the oxygen density of the exhaust gas to detect whether the air/fuel mixture is lean or rich in relation to the optimum air/fuel mixture.

When the ECU is in the oxygen sensor feedback mode, it controls combustion by making the fuel injection amount of the injector rich or lean through the signal from the sensor.

1-12 GENERAL INFORMATION

Technical Information – Oxygen Sensor

Construction and Operation

The oxygen sensor uses, a solid electrolyte called zirconia.

An electrolyte is a substance that has positive (+) and negative (−) ions and can move freely in a liquid.

For explanation purposes, picture a solid electrolyte plate as a wall and chambers A and B are divided by this wall. If both sides of the wall have platinum electrodes with holes, the difference in oxygen density (weight) between chambers A and B will move the oxygen from the chamber of higher oxygen density to the chamber of lower oxygen density until the two chambers are about equal in density. What actually moves are the oxygen ions (−) through the wall of the solid electrolyte.

The higher-density-side chamber will receive the “Pt” electrode surface with holes on the solid electrolyte wall and will become minus the oxygen ions (O2−). At this point, the O2− ions reach the “Pt” electrode of the opposite side.

Since the result of this O2− move also brings movement of “e−” (just like “cells” work in a battery), voltage will be built within the sensor.

The (conceptual) sectional view of the actual element in the oxygen sensor is shown. The sensor is exposed to exhaust gas. The shape of the sensor is tubular since the atmospheric side and exhaust gas side are parted by the wall. That means that the inside of this tubular solid electrolyte is the atmosphere side (higher oxygen density), and the outside of the tube faces the exhaust gas. The outside surface, which is in the stream of exhaust gases, has a coated layer of porous ceramic. Voltage is generated and can be measured because of the difference in oxygen density (positive and negative ions).

GENERAL INFORMATION 1-13

Technical Information – Oxygen Sensor

The sensor, uses the fresh air as the oxygen reference, and consists of a passageway to lead the fresh air inside the tubular element. Installed in this passageway is, a air permeable filter that allows the fresh air to pass through, but won’t allow moisture through. This keeps the sensor in touch with the atmosphere.

At a normal temperature, Zirconia (solid electrolyte) is an insulator and not able to sense the gases. Since the exhaust gas temperature does not become hot instantly, it takes sometime before the sensor starts to work. To solve the problem of the slow temperature increase of exhaust gases (which warms the electrolyte element), a built -in heater located inside the tubular element increases the temperature of the sensor so it can operate at a low exhaust gas temperature. Furthermore this built-in heater helps keep the sensor at a constant temperature.

Air/Fuel Ratio Control By Oxygen Sensor

”λ=1” indicates the optimum air/fuel ratio point, meaning the air/fuel ratio at which optimum (complete) combustion can be obtained. In the proximity of this mixture, the purification efficiency of the catalyst will be maximized.

The purification ratio of the three kinds of gas, HC (hydrocarbons), CO (carbon monoxide), Nox (nitrogen oxides) using the ternary (three) catalyst is shown in Fig. 4.

The best purification rate is at the zone where the oxygen sensor’s signal shows the sharp changes. This zone is called the “window” and if the oxygen sensor signal moves back and forth between the rich side (fuel rich) and lean side (fuel lean) from the oprimum mix ratio (but still within the width of the window), it indicates that the exhaust gas is in a good purification rate zone.

1-14 GENERAL INFORMATION

Technical Information – Oxygen Sensor

Figure 5 shows how the sensor operates the controlling factors.

There is a sharp voltage drop of about 1V (in reality, about 0.9 V) the sensor uses for control (a standard reference). By utilizing this voltage and using 0.45 V as the reference line, an output larger than the line indicates that exhaust gas is in the lean zone. So, when the system senses a “rich” condition through the sensor’s output voltage, it controls the fuel injection amount to make the fuel gradually leaner. When it reaches a leaner point, the sensor voltage signal drops sharply at the proximity λ=1 and goes below 0.45V. The system, at this level, senses that it has changed to “lean” and reverse the voltage signal to make the fuel richer. It then controls the fuel injection amount to make the fuel gradually richer. When it drops to a richer point, the signal drops sharply at the proximity λ=1 and goes over 0.45V. The system, at this level, senses that it has changed to “rich” and reverse the signal to make the fuel leaner. By having the signal repeat back and forth between the rich and lean sides, it can constantly stay within the window of the good purification rates. Thereby the oxygen sensor, works as a combustion control sensor for the optimum air/fuel ratio.

GENERAL INFORMATION 1-15

Technical Information – Oxygen Sensor

Maintenance

1)Periodic Inspections

Periodic inspections or special maintenance is not required for the sensor.

2)Oxygen Sensor Removal and Installation

Handle the oxygen sensor with care. Be careful not to damage sensor wires. Do not service the oxygen sensor while it is hot and not use an inpact wrench while removing or installing the oxygen sensor.

Avoid the fouling (damaging) of the sensing part of the sensor with foreign substances such as coolant, battery fluid, anti-corrosion fluid, and brake fluid.

Stop using the sensor if it is fouled with these substances.

Also stop using the sensor if the head part of the sensor (exposed to the atmosphere) is fouled. Since the sensor has a filter that allows air to escape but stop water, fouling of the sensor head may clog this filter.

Being subjected to a flame is also unacceptable for the sensor with the same reason as above.

3)Condition of the Sensor

Perform resistance measurements and visually check for scars, bends, and clogging of the sensor filter.

4)If trouble with the sensor occurs, one of the following service codes will be displayed. Accordingly, follow the related procedures in the Service Manual for necessary maintenance.

1-16 GENERAL INFORMATION

Technical Information – Electric Solenoid Operated Decompressor

An automatic decompressor (Automatic Compression Reliese) system is installed to the right side of the engine. This decompressor is activated by an electric solenoid to make starting engine easy. When the ignition is switched on and the starter button depressed, the solenoid pulls a fulcrum-mounted link that depresses push rods in each camshaft.

The push rods activate the decompression mechanism to partially open the exhaust valves as the piston nears top dead center, releasing some of compression that can cause resistance during starting.

Releasing the starter button de-activates the solenoid and a spring returns the push rods to their normal operating position.

GENERAL INFORMATION 1-17

Technical Information – Dual Balancer Shaft System

Dual balancers harmonize primary balance and reduce vibration.

The VN2000-A1 engine applied two balancer shafts, one [1] is located in front of the front cylinder and another one [2] is behind the rear cylinder.

Each balancer shaft is driven by the chain which driven to the counterclockwise by crankshaft sprocket that rotate to the clockwise viewed from the righr side.

The hydraulically operated chain tensioner is located between crankshaft and rear balancer shaft.

The hydraulic chain tensioner is supplied the oil pressure from lubrication feed pump.

Two chain guides applied, one is between the crankshaft and front balancer shaft and another is under the crankshaft sprocket.

1-18 GENERAL INFORMATION

Technical Information – Dual Balancer Shaft System

GENERAL INFORMATION 1-19

Units of Temperature:

PERIODIC MAINTENANCE 2-1

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected.

Periodic Inspection:

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

Periodic Replacement Parts:

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

2-10 PERIODIC MAINTENANCE

Torque and Locking Agent