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Kawasaki Vulcan 800 VN800 (1995-2006) Maintenance Schedule and Service Intervals

2003-2005 Kawasaki Vulcan 800 Stock Image

This is the maintenance schedule with associated service intervals for the Kawasaki Vulcan 800.

The Kawasaki Vulcan is a cruiser style motorcycle that Kawasaki made between 1995 and 2006. It didnt’ change fundamentally in that time, always being a 805cc water-cooled V-twin, with a single carburettor, five speed transmission, and (a bit unusually for a cruiser) a chain drive.

The first VN800 was a VN800A, and Kawasaki introduced a more “retro” VN800B in 1996 with full fenders and 16 inch front and rear wheels. In 1999 Kawasaki made the VN800C Vulcan 800 Drifter, another styling option.

Kawasaki Vulcan VN800C Drifter
Vulcan 800 Drifter

All the Kawasaki Vulcan 800 models were discontinued in 2006 after the Vulcan 900 was introduced.

Maintenance Schedule for Kawasaki Vulcan 800

Below is the maintenance schedule for the 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 Kawasaki Vulcan 800 is broken into two sections: Emission Related, and Non-Emission Related.

Notes on reading the maintenance chart:

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

.OperationEvery800 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)
Emission Related:
Idle speed–adjust
Throttle grip play–check †
Spark plug–clean and gap †
Valve clearance – check †
Air cleaner element –clean
Fuel system–check
Evaporative emission control system (c)–check †
Non-Emission Related:
Brake play – check †
Brake light switch — check †
Brake lining or pad wear– check †
Brake fluid level — check †month
KBrake fluid – change2 years
Clutch – adjust
KSteering –check †
Drive chain wear – check † #
Nuts, bolts, and fasteners tightness – check †
KSpoke tightness and rim runout – check
Tire wear–check †
Engine oil–changeyear
Oil filter–replace
General Lubrication–perform
KFront fork oil–change
KSwingarm pivot, uni-trak linkage — lubricate
KBrake camshaft – lubricate2 years
KCoolant–change2 years
Radiator hoses, connections–check †year
KSteering stem bearing–lubricateyear
KMaster cylinder cup and dust seal–replace2 years
KCaliper piston seal and dust seal–replace2 years
KBrake cable – replace2 years
KBrake hose –replace4 years
KBrake hose connections – check †
KFuel hose connections – check †
KFuel hose–replace4 years
Drive chain – lubricate #Every 300 km (200 mi)
Drive chain slack – check † #Every 800 km (500 mi)

Tyre size and tyre pressure for the Kawasaki Vulcan 800

The Kawasaki Vulcan 800 has the following tyres and tyre sizes standard (tube-type):


  • 80/90-21 48H
  • DUNLOP D404F


  • 140/90-16 71H
  • DUNLOP D404

The manual for the 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 Kawasaki Vulcan 800

The Kawasaki Vulcan 800 is an early predecessor to the Vulcan 900, which took over the mantle in 2006.

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 Kawasaki Vulcan 800

Maintenance Schedule Screenshot From Manual 2003-2005 Kawasaki Vulcan 800.
User manual screenshot 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.

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