This is the maintenance schedule with associated service intervals for the 2003-2005 Kawasaki Vulcan 800.
The Kawasaki Vulcan is a cruiser style motorcycle. The Vulcan name has been used for custom or cruiser motorcycles since 1984, model designation VN, using mostly V-twin engines ranging from 125 to 2,053 cc (7.6 to 125.3 cu in).
This maintenance schedule applies to the following models:
- 2003 Kawasaki Vulcan 800
- 2004 Kawasaki Vulcan 800
- 2005 Kawasaki Vulcan 800
The first Vulcan 800, also known as the VN800A, was introduced in 1995 and featured a Softail design with a bobbed rear fender and large front wheel. It had an 805 cc liquid-cooled four valves per cylinder V-twin with a five-speed transmission with optional slap shift.
The later, retro-styled VN800B debuted a year later in 1996 and featured full fenders and 16” front and rear wheels. Both of these Vulcan 800 models were discontinued in 2006 after the VN900 was introduced.
Maintenance Schedule for 2003-2005 Kawasaki Vulcan 800
Below is the maintenance schedule for the 2003-2005 Kawasaki Vulcan 800.
The following is the list of maintenance operations and to be done on this motorcycle with a time or distance interval — whichever comes earlier.
The maintenance for the 2003-2005 Kawasaki Vulcan 800 is broken into two sections: Emission Related, and Non-Emission Related.
Periodic Maintenance Chart
|.||Operation||Every||800 km (500 mi)||5000 km (3000 mi)||10000 km (6000 mi)||15000 km (9000 mi)||20000 km (12000 mi)||25000 km (15000 mi)||30000 km (18000 mi)|
|Throttle grip play–check †||•||•||•||•|
|Spark plug–clean and gap †||•||•||•||•||•||•|
|Valve clearance – check †||•||•||•||•|
|Air cleaner element –clean||•||•||•||•|
|Evaporative emission control system (c)–check †||•||•||•||•||•||•||•|
|Brake play – check †||•||•||•||•||•||•||•|
|Brake light switch — check †||•||•||•||•||•||•||•|
|Brake lining or pad wear– check †||•||•||•||•||•||•|
|Brake fluid level — check †||month||•||•||•||•||•||•||•|
|K||Brake fluid – change||2 years||•|
|Clutch – adjust||•||•||•||•||•||•||•|
|K||Steering –check †||•||•||•||•||•||•||•|
|Drive chain wear – check † #||•||•||•||•||•||•|
|Nuts, bolts, and fasteners tightness — check †||•||•||•||•|
|K||Spoke tightness and rim runout – check||•||•||•||•||•||•||•|
|Tire wear–check †||•||•||•||•||•||•|
|K||Front fork oil–change||•|
|K||Swingarm pivot, uni-trak linkage — lubricate||•||•||•|
|K||Brake camshaft – lubricate||2 years||•|
|Radiator hoses, connections–check †||year||•||•||•||•|
|K||Steering stem bearing–lubricate||year||•|
|K||Master cylinder cup and dust seal–replace||2 years|
|K||Caliper piston seal and dust seal–replace||2 years|
|K||Brake cable – replace||2 years|
|K||Brake hose –replace||4 years|
|K||Brake hose conncetions – check †||•||•||•||•||•||•|
|K||Fuel hose connections – check †||•||•||•||•||•||•|
|K||Fuel hose–replace||4 years|
|Drive chain – lubricate #||Every 300 km (200 mi)|
|Drive chain slack – check † #||Every 800 km (500 mi)|
K: Should be serviced by an authorized Kawasaki dealer
*: For higher odometer readings, repeat at the frequency interval established here
†: Replace. add. adjust, or torque if necessary.
(c): California model only
#: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
Tyre size and tyre pressure for the 2003-2005 Kawasaki Vulcan 800
The 2003-2005 Kawasaki Vulcan 800 has the following tyres and tyre sizes standard (tube-type):
- 80/90-21 48H
- BRIDGESTONE EXEDRA L307 or
- DUNLOP D404F
- 140/90-16 71H
- BRIDGESTONE EXEDRA G544 or
- DUNLOP D404
The manual for the 2003-2005 Kawasaki Vulcan 800 recommends the following tyre pressures (when cold):
- Front Up to 97.5 kg (215 lb) load – 200 kPa/28 psi
- Rear 97.5 – 181 kg (215-399 lb) load – 225 kPa/32 psi
General information about the 2003-2005 Kawasaki Vulcan 800
Powering the Vulcan 800 is a rubber-mounted 805cc V-twin engine with a single-pin crankshaft, and a gear-driven balancer to reduce vibration. Finned cylinders and four-valve heads are liquid cooled for optimum thermal control. Concealed automatic cam chain tensioners preserve the engine’s clean lines, while simultaneously allowing maintenance-free, precise cam timing. A spin-on oil filter helps keep maintenance at a minimum.
The 36mm Keihin carburetor is equipped with an accelerator pump for quick throttle response. To take advantage of the engine’s broad torque curve, the five-speed transmission enhances the strong acceleration and creates a relaxed engine pace at highway speeds. The transmission also features Kawasaki’s Positive Neutral Finder, which simplifies finding neutral while at a stop.
The single backbone, double-cradle frame design gives the Vulcan 800 stability at highway speeds and maneuverability on city streets. At the rear of the frame, a sleek, triangulated steel swingarm and hidden Kawasaki UNI-TRAK® linkage rear suspension system provide a smooth ride while maintaining the look of a hard-tail cruiser. Upfront, the 41mm front fork aids in handling and offers a wide stance for the cruiser look.
Manual for the 2003-2005 Kawasaki Vulcan 800
The above maintenance schedule comes directly from the user’s manual for the 2003-2005 Kawasaki Vulcan 800, which is available here.