2000 kawasaki voyager service manual

Kawasaki ZG1200 Voyager (Voyager XII): review, history, specs

Class: tourer

Production: 1986-2003

Also called: Kawasaki Voyager 1200, Kawasaki Voyager XII

Predecessor: Kawasaki ZN1300 Voyager XIII

Specifications

Kawasaki ZG1200 Voyager XII: specs.

Kawasaki ZG1200 Voyager XII: images, gallery.

Kawasaki ZG1200 Voyager XII: video.

Kawasaki ZG1200 Voyager XII: manuals, parts, microfiches.

• Kawasaki ZG1200 Voyager: Service Manual, 1986
• Kawasaki ZG1200 Voyager: Parts Catalog
• ↑ Motorcycle Consumer News (MCN) "Performance Index 2015" | Kawasaki Voyager XII (04/1999) | Average MPG
• ↑ Motorcycle Consumer News (MCN) "Performance Index 2015" | Kawasaki Voyager XII (04/1999) | 0-60 mph
• ↑ Motorcycle Consumer News (MCN) "Performance Index 2015" | Kawasaki Voyager XII (04/1999) | Top speed

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Repair Manual 2000 VoyagerXII

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Kawasaki Voyager 1200 Specs, Manuals, & Info

Taking care of a task for your license or motorcycle? Be prepared to satisfy any motorcycle insurance requirements.

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If you’ve got a Voyager 1200 that you’re working on, you’ve come to the right place.

Whether you’re doing a full rebuild or restoration motorcycle project or you just need to complete some routine maintenance, we’ve got all the information and links to what you need to do the job right.

On this page you’ll find:

• Links to the motorcycle service manual for your Voyager 1200.
• Where you can find used Voyager 1200s for sale to start a new motorcycle project or get a parts bike.
• Specs, details, and information about the history of the Voyager 1200.

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Voyager 1200 Specs & Details

The Voyager 1200, also known as the ZG1200 or Voyager XI/XII, was a touring motorcycle produced by Kawasaki from 1986 to 2003.

Specs for the Kawasaki Voyager 1200 include:

• Engine Displacement : 1196cc
• Cylinders/Engine Type: Transverse four cylinder liquid cool DOHC 4 stroke.
• Compression Ratio : 10:1
• Transmission : 6 speed
• Wet Weight: 698 lbs

Find a Voyager 1200 for Sale Near You

If you’re looking for a Voyager 1200 of your own or need a donor parts bike for your current motorcycle project, you can use the MotorcycleZombies.com used bike search tool to find what you’re looking for.

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Once you’ve got the bike up and running, be sure to check back to our motorcycle registration and title guides if you need help getting plates (Especially if you’ve bought the Voyager 1200 without a title ).

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Kawasaki Motorcycles & ATVs: Service Repair Manuals PDF

Kawasaki is a global brand specializing in the production of various equipment. In addition to the usual motorcycles, the company produces aircraft, ships and other large equipment using the most modern technologies. The Kawasaki company, whose history has long roots, remains one of the prominent players in the market for the production of various equipment.

Kawasaki company began to produce motorcycles quite late, skipping the 50s of the last century, when the entire industry in Japan began to increase its pace of development. It was during this time period that the transition began not only to the Asian market, but also to the countries of Europe and America. The initial goal of all firms in Japan engaged in the production of various equipment was the desire to provide the population with the equipment that could be some kind of alternative to public transport. Obviously, in the early years, the results could hardly have been high, but the growth trend, of course, was outlined.

The refinement of technological processes, and then participation in various world competitions, laid the foundation for the formation of future success.

The founder of the company is Shozo Kawasaki, who comes from the family of a simple kimono seller. The beginning of Shozo’s career was not at all connected with motor vehicles, he started with the job of a seller, later got a merchant ship. 1876 in the life of Shozo was marked by the fact that he opens his own shipyard and begins to occupy a leading position in the sugar trade.

The history of kawasaki dates back to the shipyard that was founded by Shouzo Kawasaki. Gradually, this company expanded, starting its activities in other industries, including civil and railway construction. In 1911, the company focused on organizing shipping, and then the company began building aircraft and its components. The Chinese-Japanese war gave a new impetus Kawasaki’s business development, making it possible to provide repairs to all military vessels and other equipment. After the war, Shozo Kawasaki decides to make Kozhiro Matsukata, who became the first president of the Kawasaki concern, as manager. This position was assigned to him for thirty-two years, during which time he introduced an 8-hour work week, which was an innovation in those days.

Since the moment when Japan began active hostilities, Kawasaki became the main supplier of various equipment for the army. The situation changed radically after the war, then the company experienced a real decline in its production. The first gaps of the upcoming progress appeared in 1950, when the first engine was designed at one of the plants. In 1951, production technologies for 2-stroke and 4-stroke engines were installed, which were installed on bicycles from the Noriz company.

1954 - More than two hundred Bikescooter KV-2 scooters were released. The next step of the company was the joint production of Meihazu 60 - a bicycle with an outboard engine.

1957 - during this period, mass production and production of motorcycle equipment begins. Initially, they went under the Meihazu brand, but since 1961, the Kawasaki brand was finally approved. 1966 - expansion begins on the American market, however, this does not bring definite success. And in 1975 this process was slightly stopped and the company decided to return to the Japanese market.

Kawasaki Samurai

In 1966, the first Samurai kawasaki motorcycles appeared, equipped with a special dual pipe system located at the rear. The motorcycle had an engine of 90 cm3 and a 5-speed gearbox. This model was a true leader for five years, until Honda began to produce motorcycles of this type.

Kawasaki Mach III

1968 - this date became the moment of mass production of Mach III motorcycles, samples of which immediately began to be delivered to European countries. This model was a real discovery among motorcycles of this type, having engines with a volume of 500 cm3. 1973 - The company launches the H2 750 Mach IV with an improved design.

Following the success of the MachIII, the company launches the new Z1 motorcycle, which is widely recognized. Without stopping at this, the designers begin to work on the continuation of the series and release the Z2. There are no special differences between them, except for the engine, which was reduced to 750 cm3.

Kawasaki in 1977-1979

1977 was marked by the fact that the production of Z1000 and Z1000LTD, having a volume of about 1016 cm3, was started. The production of the Z650C begins, which is distinguished by titanium wheels and an engine capacity of 652 cm3. 1978 - The Z400 was equipped with a 6-speed gearbox, and Z650SR motorcycles were also produced. 1979 - Kawasaki launches the ZI3000, which has a 6-speed gearbox and a 1286 cm3 engine. Being a rather bulky machine, this model nevertheless aroused considerable interest among buyers.

80s in the history of the brand

1983 - release of the AR 125 model begins, having a volume of 125 cm3. A 6-speed gearbox and a liquid-based cooling system make it one of the most popular models of the time. In 1985, continued growth in the production of 4-stroke motorcycles. So, the LTD450 based on the Ninja engine was born. 1988 - the engine is increased to one thousand cm3, resulting in the appearance of the ZX10 model, which has an aluminum frame in the design. The end of the 80s was marked by an increased interest in “retro” models, when the nostalgic design was combined with the latest technological innovations.

90s in the history of Kawasaki

At this time, production work focused on sports types of motorcycles began to develop rapidly. On the basis of Kawasaki, the ZZ-R appeared, which belongs to the class of machines with a volume of up to one thousand cm3. Along the way, the retro style in the development of motorcycles developed, for example, the ZXR bike was released, combining the original design and powerful technological “stuffing.” 1992 - the Estrella bike belonging to the category of motorcycles up to 249 cm3 was born. This model has become very popular in Japan, as evidenced by the high sales figures recorded at that time. 1998 - a model with a volume of 125 cm3 and a 4-stroke engine is produced. At the same time in the United States, Vulcan Nomad, a motorcycle with a 2-cylinder engine, was in full swing. 1999 - release of the Drifter model, which has the design of past years. In general, the end of the century for the company Kawasaki was marked by the release of models based on the improvement of already released motorcycles, thus practically stopping the serial production of new models.

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service manual

Moderators: the2knights , Highway Rider

Post by twopass » Mon Apr 25, 2011 12:11 am

Re: service manual

Post by richardb, austin » Mon Apr 25, 2011 2:45 am

Post by HMB Don » Tue Apr 26, 2011 4:00 pm

Post by voyager99 » Thu Apr 28, 2011 3:59 pm

Post by flip18436572 » Fri Apr 29, 2011 1:19 am

Post by runnfree » Mon Aug 13, 2012 2:49 am

Post by SgtSlag » Mon Aug 13, 2012 12:55 pm

Post by runnfree » Mon Aug 13, 2012 1:01 pm

Post by xtree1 » Thu Sep 06, 2012 7:46 pm

Post by SgtSlag » Thu Sep 06, 2012 10:06 pm

Post by kjsett » Fri Oct 19, 2012 6:23 pm

Post by Gator Mike » Fri Oct 19, 2012 7:21 pm

Post by kjsett » Fri Oct 19, 2012 9:21 pm

Post by gearheadfla » Fri Oct 19, 2012 10:15 pm

Gator Mike wrote: Ken to my knowledge the manual is the same for all models. The only thing that changed was covered in the supplement. The bike changed very little over it's history. .......Gator Mike

Post by Mr Jensee » Tue Oct 23, 2012 3:10 pm

Return to “General - Voyager XII (1200 Four)”

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OWNER'S AND SERVICE MANUALS

Welcome, Kawasaki owners. Access the information and tools you need to get the most out of your vehicle.

2000 Vulcan ® 1500 Classic

Service Manual Supplement* VN1500D/E

Item# 99924-1191-52

Service Manual Supplement* VN1500E

Item# 99924-1229-56

Owner’s Manual VN1500-E3 (2000)

Item# 99920-1963-01

Printed manual no longer available. Please view the manual online free of charge

NOTE: Kawasaki attempts to keep our Owners and Service Manuals library as complete as possible. However, some manuals may have sold out or are no longer available. Check your specific model for Owners and Service Manual availability.

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LIST OF ABBREVIATIONS

Units of mass:, units of volume:, units of force:, units of length:, units of torque:, units of pressure:, units of speed:, units of power:.

• Periodic Inspection:
• Periodic Replacement Parts:
• Basic Torque for General Fasteners
• Pad Lining Thickness
• Air Pressure (when cold)
• Tread Depth
• Clutch Lever Free Play
• Drive Belt Wear and Damage Analysis
• Sidestand Switch Operation
• Throttle Grip Free Play
• Water and Coolant Mixture Ratio (when shipping)
• Sample Diagnosis Sheet
• Poor Running at Low Speed
• Poor Running or No Power at High Speed:
• Main Throttle Sensor Input Voltage
• Input Voltage at ECU Connector
• Main Throttle Sensor Output Voltage
• Output Voltage at ECU
• Main Throttle Sensor Resistance
• Inlet Air Pressure Sensor Input Voltage
• Input Voltage at ECU
• Inlet Air Pressure Sensor Output Voltage
• Inlet Air Pressure Sensor Output Voltage Connection to Sensor
• Inlet Air Temperature Sensor Output Voltage
• Inlet Air Temperature Sensor Resistance
• Water Temperature Sensor Output Voltage
• Water Temperature Sensor Resistance
• Atmospheric Pressure Sensor Input Voltage
• Atmospheric Pressure Sensor Output Voltage
• Output Voltage
• Speed Sensor Input Voltage
• Input Voltage at Sensor
• Throttle Sensor Output Voltage
• Output Voltage at Sensor
• Gear Position Switch Input Voltage at Neutral Position
• Gear Position Switch Input Voltage at Other Gear Positions
• Input Voltage at Neutral Position
• Input Voltage at Other Gear Positions
• Vehicle-down Sensor Power Source Voltage
• Vehicle-down Sensor Output Voltage
• Subthrottle Sensor Input Voltage
• Subthrottle Sensor Output Voltage
• Throttle Sensor Resistance
• Oxygen Sensor Output Voltage
• Oxygen Sensor Output Voltage (with Plugs)
• Oxygen Sensor Output Voltage (without Plugs)
• Oxygen Sensor Resistance
• Injector Fuel Line Maximum Pressure
• Injector Power Source Voltage at ECU Main Relay
• Injector Output Voltage at ECU
• Injector Wiring Inspection
• Injector Resistance
• Pump Operating Voltage at Pump
• Pump Power Source Voltage
• Pump Operating Voltage at Pump Connector
• Ignition Coil Input Voltage at ECU
• Subthrottle Valve Actuator Resistance
• Subthrottle Valve Actuator Input Voltage
• Oxygen Sensor Power Source Voltage
• ECU Grounding Inspection
• ECU Power Source Inspection
• Fuel Pressure
• Fuel Pressure (idling)
• Amount of Fuel Flow
• Radiator Cap Relief Pressure
• Thermostat Valve Opening Temperature
• Spring Free Length
• Camshaft Chain 20-link Length
• Cylinder Compression (Usable Range)
• Temporary Torque
• Cylinder Head Warp
• Valve-to-Guide Clearance (Wobble Method)
• Valve Seat Surface Outside Diameter (Seat O.D.)
• Valve Seat Surface Width (or Seat Width)
• [For Exhaust Valve Seat]
• [For Inlet Valve Seat]
• Cylinder Inside Diameter
• Piston Diameter
• Piston Ring/Groove Clearance
• Piston Ring Groove Width
• Piston Ring Thickness
• Piston Ring End Gap
• Primary Chain 20–Link Length
• Clutch Plate Assembly
• Friction Plate Thickness
• Friction or Steel Plate Warp
• Clutch Spring Free Length
• Oil Pressure
• Connecting Rod Bend
• Connecting Rod Twist
• Connecting Rod Big End Side Clearance
• Connecting Rod Big End Bearing/Crankpin Clearance
• Crankpin Diameter
• Crankpin Diameter Marks
• Connecting Rod Big End Bore Diameter Marks
• Big End Bearing Insert Selection
• Crankshaft Runout
• Crankshaft Main Journal Diameter
• Crankcase Main Bearing Bore Diameter
• Crankshaft Side Clearance
• Crankshaft Web Length
• Shift Fork Ear Thickness
• Gear Groove Width
• Shift Fork Guide Pin Diameter
• Shift Drum Groove Width
• Axle Runout/100 mm (3.94 in.)
• Balance Weight
• Pedal Position
• Front Disc Thickness
• Rear Disk Thickness
• Disc Runout
• Front Fork Oil Level (Fully compressed without fork spring)
• Rebound Damping Force Adjustment
• Spring Preload Setting Length
• Spring Adjustment
• Kawasaki-recommended chargers:
• Battery Terminal Voltage
• Terminal Voltage: 11.5 ~ less than 12.6 V
• Terminal Voltage: less than 11.5 V
• Battery Charging Voltage
• Alternator Output Voltage
• Stator Coil Resistance
• Regulator/Rectifier Resistance (Unit: kΩ)
• 3 Needle Arcing Distance
• Ignition Coil Winding Resistance
• Recommended Tool: Peak Voltage Adapter
• Primary Lead Connections:
• Ignition Coil Primary Peak Voltage
• Connections:
• Crankshaft Sensor Peak Voltage
• Crankshaft Sensor Resistance
• Starter Motor Brush Length
• Commutator Diameter
• Testing Relay
• Connections
• Testing Turn Signal Control Relay Inspection
• Fuel Level Warning Indicator LED Light Connections:
• Oil Pressure Warning Indicator LED Light Connections:
• FI Indicator LED Light Connections:
• Water Temperature Warning Indicator LED Light Connections:
• Neutral Indicator Light Connections:
• High Beam Indicator Light Connections:
• Air Switching Valve Resistance
• Decompression Solenoid Resistance
• Fuel Level Sensor Resistance
• Gear Position Switch Resistance
• Relay Circuit Inspection (with the battery disconnected)
• Relay Circuit Inspection (with the battery connected)
• Diode Circuit Inspection

EMISSION CONTROL INFORMATION

Tampering with noise control system prohibited, general information, battery ground, edges of parts, cleaning vehicle before disassembly, arrangement and cleaning of removed parts, storage of removed parts, replacement parts, assembly order, tightening sequence, tightening torque, liquid gasket, locking agent, ball bearing and needle bearing, oil seal, grease seal, circlips, cotter pins, lubrication, direction of engine rotation, electrical wires, vn2000-a1 (us, and canada) left side view:, vn2000-a1 (us, and canada) right side view:, vn2000-a1 (europe) left side view:, vn2000-a1 (europe) right side view:, construction and operation, air/fuel ratio control by oxygen sensor, maintenance, prefixes for units:, units of temperature:.

• Periodic Maintenance
• Inside Circlip Pliers: 57001–143
• Steering Stem Nut Wrench: 57001–1100
• Jack: 57001–1238
• Oil Filter Wrench: 57001–1249
• Spark Plug Wrench, Hex 16: 57001–1262
• Jack Attachment : 57001–1571
• Drive Belt Tension Gauge: 57001– 1585
• Steering System:
• Steering Play Inspection
• Steering Play Adjustment
• Steering Stem Bearing Lubrication
• Brake System:
• Brake Fluid Leak (Brake Hose and Pipe)
• Brake Hose Damage and Installation Connection Inspection
• Brake Operation Inspection
• Brake Fluid Level Inspection
• Brake Pad Wear Inspection
• Brake Light Switch Operation
• Wheel and Tires:
• Tire Air Pressure Inspection
• Wheel/Tire Damage Inspection
• Tire Tread Wear Inspection
• Wheel Bearing Damage Inspection
• Suspensions
• Front Forks/Rear Shock Absorber Operation Inspection
• Front Fork Oil Leak Inspection
• Rear Shock Absorber Oil Leak Inspection
• Swingarm Pivot Lubrication
• Clutch and Drive Train:
• Clutch Operation
• Belt Deflection Inspection
• Belt Deflection Adjustment
• Wheel Alignment Inspection/Adjustment
• Belt Wear and Damage Inspection
• Drive Belt Tooth Wear and Damage Patterns
• Electrical System:
• Spark Plug Condition Inspection
• Lights and Switches Operation
• Headlight Aiming Inspection
• Side Stand Switch Operation Inspection
• Engine Stop Switch Operation Inspection
• Fuel System (DFI):
• Throttle Control System Inspection
• Idle Speed Inspection
• Fuel Hose and Connection Inspection
• Cooling System
• Coolant Level Inspection
• Radiator Hose and Connection Inspection
• Evaporative Emission Control System Inspection (CAL):
• Evaporative Emission Control System Inspection
• Air Suction System:
• Air Switching Valve Operation Test
• Chassis Parts Lubrication
• Bolts and Nuts Tightness Inspection
• Replacement Parts:
• Brake Hose and Pipe Replacement
• Brake Fluid Change
• Master Cylinder Rubber Parts Replacement
• Silicone Grease -
• Caliper Rubber Parts Replacement
• Spark Plug Replacement
• Air Cleaner Element Replacement
• Engine Oil Change
• Oil Filter Replacement
• Fuel Hose Replacement
• Coolant Change
• Radiator Hose and O-ring Replacement
• Fuel System (DFI)
• Oil Pressure Gauge, 5 kg/cm² : 57001–125
• Fork Oil Level Gauge : 570101–1290
• Hand Tester : 57001–1394
• Fuel Pressure Gauge Adapter : 57001–1593
• Needle Adapter Set : 57001–1457
• Kawasaki Bond (Silicone Sealant) : 56019–120
• Throttle Sensor Setting Adapter: 57001–1400
• Fuel Hoses: 57001–1607
• DFI System Wiring Diagram
• DFI Diagnosis Flow Chart
• Inquiries to Rider
• Self-diagnosis Outline
• Self-diagnosis Procedures
• Service Code Clearing Procedures
• How to Read Service Codes
• How to Erase Service Codes
• Service Code Table
• Main Throttle Sensor Removal/Adjustment
• Input Voltage Inspection
• Output Voltage Inspection
• Resistance Inspection
• Installation
• Removal/Installation
• Sensor Resistance Inspection
• Water Temperature Sensor Resistance Inspection
• Atmospheric Pressure/Altitude Relationship
• Crankshaft Sensor Removal/Installation
• Crankshaft Sensor Inspection
• Camshaft Position Sensor Removal/Installation
• Camshaft Position Sensor Inspection
• Speed Sensor Removal/Installation
• Speed Sensor Inspection
• Gear Position Switch Removal/Installation
• Gear Position Switch Inspection
• Vehicle-down Sensor Removal
• Vehicle-down Sensor Inspection
• Subthrottle Sensor Removal/Adjustment
• Oxygen Sensor Removal/Installation
• Oxygen Sensor Inspection
• Oxygen Sensor Heater Inspection
• Injector Removal
• Injector Installation
• Audible Inspection
• Power Source Voltage Inspection
• Injector Signal Test
• Injector Resistance Inspection
• Injector Unit Test
• Fuel Pump Removal
• Fuel Pump Installation
• Pressure Regulator Removal
• Pump Screen, Fuel Filter Cleaning
• Operation Inspection
• Operating Voltage Inspection
• Starter Control Relay Removal and Installation
• Starter Control Relay Inspection
• Radiator Fan Relay Removal/Installation
• Radiator Fan Relay Inspection
• Subthrottle Valve Actuator Removal
• Subthrottle Valve Actuator Inspection
• Air Switching Valve Removal/Instalation
• Air Switching Valve Inspection
• Decompression Solenoid Removal/Installation
• Decompression Solenoid Inspection
• Oxygen Sensor Heater Removal/Installation
• Subthrottle Motor Driver Removal/Installation
• Subthrottle Motor Driver Inspection
• Inspection Flow Chart
• LED Light Inspection
• ECU Removal
• ECU Installation
• ECU Power Supply Inspection
• Fuel Pressure Inspection
• Fuel Flow Rate Inspection
• Throttle Grip Free Play Inspection
• Throttle Grip Free Play Adjustment
• Cable Removal/Installation
• Cable Lubrication and Inspection
• Idle Speed Check
• Idle Speed Adjustment
• Throttle Bore Cleaning
• High Altitude Performance Adjustment
• Throttle Body Assy and Intake Manifold Removal
• Throttle Body Assy and Intake manifold Installation
• Element Removal
• Air Cleaner Housing Removal
• Air Cleaner Housing Installation
• Fuel Tank Removal
• Fuel Tank Installation
• Fuel Tank and Cap Inspection
• Fuel Tank Cleaning
• Parts Removal/Installation
• Canister Installation
• Canister Inspection (Periodic Inspection)
• Separator Inspection (Periodic Inspection)
• Hose Inspection (Periodic Inspection)
• Separator Operation Test
• Bearing Driver Set : 57001–1129
• Bearing Remover Shaft : 57001–1265
• Coolant Deterioration Inspection
• Coolant Draining
• Coolant Filling
• Pressure Testing
• Cooling System Flushing
• Water Pump Removal
• Water Pump Installation
• Water Pump Inspection
• Mechanical Seal Replacement
• Radiator Removal
• Radiator Installation
• Radiator Inspection
• Radiator Cap Inspection
• Radiator Filler Neck Inspection
• Thermostat Removal
• Thermostat Installation
• Thermostat Inspection
• Hose Installation
• Hose Inspection
• Engine Top End
• Push Rod Length and Runout
• Valve Head Thickness
• Valve Stem Bend
• Camshaft Journals
• Compression Gauge : 57001–221
• Valve Spring Compressor Assembly : 57001–241
• Compression Gauge Adapter, M14 x 1.25 : 57001–1590
• Spark Plug Wrench, Hex 16 : 57001–1262
• Piston Ring Compressor Grip : 57001–1095
• Valve Seat Cutter Holder Bar : 57001–1128
• Piston Pin Puller Assembly: 57001–1568
• Bearing Driver Set: 57001–1129
• Air Suction Valve Removal
• Air Suction Valve Installation
• Air Suction Valve Inspection
• Air Switching Valve Removal
• Air Switching Valve Installation
• Clean Air System Hose Inspection
• Rocker Case Cover Removal
• Rocker Case Cover Installation
• Rocker Case Removal
• Rocker Case Installation
• Rocker Arm Assembly
• HLA Removal
• HLA Air Bleeding
• HLA Installation
• Decompression Mechanism Removal
• Decompression Mechanism Installation
• Oil Seal Inspection
• Spring Tension
• Camshaft Removal
• Camshaft Installation
• Ball Bearing and Outer Race Replacement
• Ball Bearing Wear
• Camshaft Chain Wear
• Cylinder Compression Measurement
• Cylinder Head Removal
• Cylinder Head Installation
• Valve Clearance Adjustment
• Valve Removal
• Valve Installation
• Valve Guide Removal
• Valve Guide Installation
• Valve Guide Wear (Wobble Method)
• Valve Seat Inspection
• Valve Seat Repair
• Cylinder Removal
• Piston Removal
• Cylinder, Piston Installation
• Cylinder Wear
• Piston Wear
• Piston Ring, Piston Ring Groove Wear
• Upper Muffler Removal
• Lower Muffler Removal
• Exhaust Manifold Removal
• Muffler, Exhaust Pipe Installation
• Clutch Holder: 57001–1243
• Flywheel & Pulley Holder: 57001–1343
• Flywheel & Pulley Holder Adapter: 57001–1547
• Kawasaki Bond (Liquid Gasket-Black): 92104–1064
• Lever Free Play Inspection
• Clutch Cable Removal
• Clutch Cable Installation
• Clutch Cable Lubrication
• Clutch Lever Installation
• Outer Clutch Cover Removal
• Outer Clutch Cover Installation
• Release Shaft Removal
• Release Shaft Installation
• Clutch Removal
• Clutch Installation
• Starter Clutch Disassembly
• Starter Clutch Assembly
• Starter Clutch Inspection
• Starter Torque Limiter Check
• Primary Chain Wear
• Clutch Plate Assembly Inspection
• Clutch Plate Assembly Adjustment
• Friction and Steel Plate Wear, and Damage Inspection
• Clutch Housing Finger Inspection
• Outer Clutch Hub Spline Inspection
• Cam Damper Inspection
• Clutch Spring Free Length Measurement
• Engine Lubrication System
• Oil Pressure Gauge Adapter, PT 1/8 : 57001–1033
• Oil Filter Wrench : 57001–1249
• Oil Level Inspection
• Oil Pump Removal
• Oil Pump Installation
• Oil Pan Removal
• Oil Pan Installation
• Blowby Gas System Inspection
• Breather Drain Cleaning
• Oil Pressure Measurement
• Relief Valve Inspection
• Engine Removal/Installation
• Jack : 57001–1238
• Socket Wrench: 57001–1347
• Jack Attachment: 57001–1571
• Engine Removal
• Engine Installation
• Crankshaft/Transmission
• Outside Circlip Pliers : 57001–144
• Gear Holder : 57001–1574
• Flywheel & Pulley Holder : 57001–1343
• Kawasaki Bond (Liquid Gasket – Black) : 92104–1064
• Flywheel & Pulley Holder Adapter 57001–1547
• Crankcase Disassembly
• Crankcase Assembly
• Connecting Rod Removal
• Connecting Rod Installation
• Crankshaft/Connecting Rod Cleaning
• Connecting Rod Big End Bearing Wear
• Molybdenum Disulfide Oil -
• Crankshaft Main Bearing/Journal Wear
• Balancer Mechanism Removal
• Balancer Mechanism Installation
• Shift Pedal Removal
• Shift Pedal Installation
• External Shift Mechanism Removal
• External Shift Mechanism Installation
• External Shift Mechanism Inspection
• Transmission Removal
• Transmission Installation
• Shift Drum Disassembly
• Shift Drum Assembly
• Transmission Disassembly
• Transmission Assembly
• Shift Fork Bending
• Shift Fork/Gear Groove Wear
• Shift Fork Guide Pin/Drum Groove Wear
• Gear Dog and Gear Dog Hole Damage
• Ball and Needle Bearing Wear
• Wheels/Tires
• Inside Circlip Pliers : 57001–143
• Bearing Remover Head, 20 x 22 : 57001–1293
• Bearing Remover Head, 25 x 28 : 57001–1346
• Bearing Remover Shaft, 13 : 57001–1377
• Front Wheel Removal
• Front Wheel Installation
• Rear Wheel Removal
• Rear Wheel Installation
• Wheel Inspection
• Axle Inspection
• Wheel Balance
• Balance Inspection
• Balance Adjustment
• Balance Weight Removal
• Balance Weight Installation
• Air Pressure Inspection/Adjustment
• Tire Inspection
• Tire Removal
• Tire Installation
• Tire Repair
• Hub Bearings Removal
• Hub Bearings Installation
• Hub Bearings Inspection
• Hub Bearings Lubrication
• Final Drive
• Inside Circlip Priers : 57001–143
• Oil Seal & Bearing Remover: 57001–1058
• Pulley Holder : 57001–1572
• Grip : 57001–1591
• Belt Handling Precautions
• Drive Belt Wear Inspection
• Drive Belt Deflection Inspection
• Drive Belt Deflection Adjustment
• Drive Belt Removal
• Drive Belt Installation
• Engine Pulley Cover Removal
• Engine Pulley Cover Installation
• Engine Pulley Removal
• Engine Pulley Installation
• Rear Pulley Removal
• Rear Pulley Installation
• Rear Pulley Coupling Removal
• Rear Pulley Coupling Installation
• Pulley Wear Inspection
• Coupling Bearing Removal
• Coupling Bearing Installation
• Coupling Bearing Inspection and Lubrication
• Rubber Damper Inspection
• Brake Lever Position Adjustment
• Brake Pedal Position Adjustment
• Brake Pedal Removal
• Brake Pedal Installation
• Front Caliper Removal
• Rear Caliper Removal
• Caliper Installation
• Front Caliper Disassembly
• Front Caliper Assembly
• Rear Caliper Disassembly
• Rear Caliper Assembly
• Caliper Fluid Seal Damage
• Caliper Dust Boot and Friction Boot Damage
• Caliper Piston and Cylinder Damage
• Caliper Holder Shaft Wear
• Front Brake Pad Removal
• Front Brake Pad Installation
• Rear Brake Pad Removal
• Rear Brake Pad Installation
• Front Master Cylinder Removal
• Front Master Cylinder Installation
• Rear Master Cylinder Removal
• Rear Master Cylinder Installation
• Front Master Cylinder Disassembly
• Rear Master Cylinder Disassembly
• Master Cylinder Assembly
• Master Cylinder Inspection
• Brake Disc Removal
• Brake Disc Installation
• Brake Disc Wear
• Brake Disc Warp
• Brake Line Bleeding
• Brake Hose Removal/Installation
• Fork Cylinder Holder Handle : 57001–183
• Fork Cylinder Holder Adapter : 57001–1057
• Oil Seal & Bearing Remover : 57001–1058
• Hook Wrench : 57001–1580
• Fork Oil Seal Driver, 49 : 57001–1589
• Fork Oil Change
• Front Fork Removal
• Front Fork Installation
• Front Fork Disassembly
• Front Fork Assembly
• Inner Tube, Outer Tube Inspection
• Dust Seal Inspection
• Spring Preload Adjustment
• Rear Shock Absorber Removal
• Rear Shock Absorber Installation
• Rear Shock Absorber Inspection
• Swingarm Removal
• Swingarm Installation
• Swingarm Bearing Removal
• Swingarm Bearing Installation
• Swingarm Bearing, Sleeve Inspection
• Grease Seal and Needle Bearing Lubrication
• Head Pipe Outer Race Press Shaft : 57001–1075
• Head Pipe Outer Race Driver : 57001–1077
• Head Pipe Outer Race Remover : 57001–1107
• Steering Stem Nut Wrench : 57001–1100
• Steering Stem Bearing Driver : 57001–1344
• Steering Stem Bearing Driver Adapter : 57001–1345
• Handlebar Removal
• Handlebar Installation
• Steering Check
• Steering Adjustment
• Steering Stem Removal
• Steering Stem Installation
• Steering Stem Warp
• Stem Bearing Removal
• Stem Bearing Installation
• Stem Bearing Lubrication
• Stem Cap Deterioration, Damage
• Rear Seat Removal
• Rear Seat Installation
• Front Seat Removal
• Front Seat Installation
• Right Side Cover Removal
• Right Side Cover Installation
• Left Side Cover Removal
• Left Side Cover Installation
• Ignition Coil Bracket Cover Removal
• Ignition Coil Bracket Cover Installation
• Front Fender Removal
• Rear Fender Removal
• Rear Fender Installation
• Tool Case Removal
• Battery Case Removal
• Right Footboard Removal
• Right Footboard Installation
• Right Footboard Disassembly
• Right Footboard Assembly
• Left Footboard Removal
• Left Footboard Installation
• Left Footboard Disassembly
• Left Footboard Assembly
• Side Stand Installation
• Downtube Removal
• Downtube Installation
• Headlight Cover Removal
• Headlight Cover Installation
• Frame Inspection
• Electrical System
• Filler Cap Driver : 57001–1454
• Needle Adapter Set: 57001–1457
• Wiring Inspection
• Battery Removal
• Battery Installation
• Battery Activation
• Precautions
• Interchange
• Charging Condition Inspection
• Refreshing Charge
• Alternator Rotor Removal
• Alternator Rotor Installation
• Alternator Stator Removal
• Alternator Stator Installation
• Charging Voltage Inspection
• Alternator Inspection
• Regulator/Rectifier Removal
• Regulator/Rectifier Installation
• Regulator/Rectifier Inspection
• Charging System Circuit
• Ignition Coil Removal
• Ignition Coil Installation
• Ignition Coil Inspection
• Spark Plug Removal
• Spark Plug Installation
• Spark Plug Cleaning/Inspection
• Crankshaft Sensor Removal
• Crankshaft Sensor Installation
• Camshaft Position Sensor Removal
• Camshaft Position Sensor Installation
• Interlock Operation Inspection
• IC Igniter Inspection
• Ignition System Circuit
• Starter Motor Removal
• Starter Motor Installation
• Starter Motor Disassembly
• Starter Motor Assembly
• Brush Inspection
• Commutator Cleaning and Inspection
• Armature Inspection
• Brush Assy Inspection
• Brush Plate and Terminal Bolt Inspection
• Starter Relay Inspection
• Electric Starter Circuit
• Headlight Beam Horizontal Adjustment
• Headlight Beam Vertical Adjustment
• Headlight Bulb Replacement
• City Light Bulb Replacement (Europe Model)
• Tail/Brake Light Bulb Replacement
• Headlight/Tail Light Circuit
• Distance Sensor Inspection
• Turn Signal Switch Inspection
• Turn Signal Switch Connections
• Turn Signal Control Relay Inspection
• Turn Signal Light Bulb Replacement
• Turn Signal Cancelling System Circuit
• Fan Motor Inspection
• Radiator Fan Circuit
• Meter Unit Removal
• Meter Unit Installation
• Meter Unit Disassembly
• Meter Unit Assembly
• Meter Unit Inspection
• Indicator Light Inspection
• Meter Unit Circuit
• Air Switching Valve Unit Test
• Fuel Level Sensor Inspection
• Fuel Reserve Switch Inspection
• Speed Sensor Removal
• Speed Sensor Installation
• Non-permanent Locking Agent -
• Oxygen Sensor Removal
• Oxygen Sensor Installation
• Front Brake Light Switch Inspection
• Rear Brake Light Switch Check/Adjustment
• Water Temperature Sensor Removal
• Water Temperature Sensor Installation
• Water Temperature Sensor Inspection
• Gear Position Switch Removal
• Gear Position Switch Installation
• Switch Inspection
• Rear Brake Light Switch Connections
• Side Stand Switch Connections
• Oil Pressure Switch Connections*
• Relay Box Removal
• Relay Circuit Inspection
• Relay Box Internal Circuit
• Main Fuse Removal
• ECU Fuse Removal
• Fuse Box Fuse Removal
• Fuse Installation
• Fuse Inspection
• Starter motor not rotating:
• No fuel flow:
• Engine flooded:
• No spark; spark weak:
• Fuel/air mixture incorrect:
• Compression Low:
• Poor Running at Low Speed:
• Spark weak:
• Compression low:
• Backfiring when deceleration:
• Firing incorrect:
• Miscellaneous:
• Overheating:
• Muffler overheating:
• Compression high:
• Engine load faulty:
• Lubrication inadequate:
• Water temperature warning system incorrect:
• Coolant incorrect:
• Cooling system component incorrect:
• Over Cooling:
• Clutch Operation Faulty:
• Clutch slipping:
• Clutch not disengaging properly:
• Gear Shifting Faulty:
• Jumps out of gear:
• Overshifts:
• Abnormal Engine Noise:
• Piston slap:
• Valve noise:
• Other noise:
• Abnormal Drive Train Noise:
• Clutch noise:
• Transmission noise:
• Drive line noise:
• Abnormal Frame Noise:
• Front fork noise:
• Rear shock absorber noise:
• Disc brake noise:
• Oil Pressure Warning Light Goes On:
• Exhaust Smokes Excessively:
• White smoke:
• Black smoke:
• Brown smoke:
• Handling and/or Stability Unsatisfactory:
• Handlebar hard to turn:
• Handlebar shakes or excessively vibrates:
• Handlebar pulls to one side:
• Shock absorption unsatisfactory:
• Battery Trouble:
• Battery discharged:
• Battery overcharged:

Kawasaki VN2000 Service Manual

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Service Manual

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I'm looking to get a Service Manual for my 2012 Voyager 1700. Who has the best one, where and how much?  

Unless you getting from an individual, I think the dealer is it, mine was I think $87?,when I bought my new bike last year, 2012 Voyager. Sent from Motorcycle.com Free App  

I live in Canada and it was close to $200.oo with all the taxes. I was down in ND for the weekend and picked it up for around $88.00. These were all factory manuals. I picked up a PDF download for free but like the factory manual better as it is paper and I am old school and find it easier to read in the garage when I am working on my bike. Just my 2 cents.  

Invest ONLY in a genuine Kawasaki service manual. It is without a doubt the most complete and comprehensive manual. DO NOT waste your money on a Haynes or Clymer manual, they are NEVER as complete as a factory service manual. RACNRAY  

I agree with Ray. I have the Clymer and later bought the factory manual, BIG, BIG DIFFERENCE!!!!! With the OEM book, the pictures are much better and the values for tests and trouble shooting are right there with the pics and or instructions. My book cost $50 with free shipping and was here in 2-3 days. The cover page looks like a copy, but the rest of the pages look great. Clear sharp pictures, no smudges. The chapters are set up a bit differently than the Clymer manual, but I am adjusting to that. So I will keep both and rely on the OEM. IN addition there is information and pictures in the OEM book that are not in the Clymer. I really, really like the OEM book.  

I only buy factory manuals, cannot beat them and I have one for sale in the apparel and accessories section http://www.vulcanforums.com/forums/showthread.php?t=150842  

You can get a CD version on ebay and Amazon for less than 20 bucks... And yes people always say... "I wpould rather have a hard copy in my hand"... Even with the hard copy that I do not want to mess up, I still print out the pages from the CD version I need and it does not matter if those get grimy.... Also good used hard copy manuals for around 50 bucks.... I have both. Got my new hard copy off ebay for $48 three years ago....  

Or free works pretty good too........  

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