Kawasaki 1700 Voyager Vulcan 2009-12 Workshop Service Manual
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The Kawasaki Voyager Vulcan 1700 is a full-size touring motorcycle designed for long-distance travel, offering a premium experience for riders. Introduced for the 2009 model year and produced through 2012, this model exemplifies Kawasaki's legacy of building reliable and powerful V-twin cruisers. Key features include a large fairing with an integrated windshield for wind protection, spacious saddlebags for ample storage, and standard electronic cruise control to enhance rider comfort on extended journeys. Its liquid-cooled, 1700cc V-twin engine delivers robust power and torque, complemented by a smooth, low-maintenance belt final drive, making it a strong contender in the touring motorcycle segment. This comprehensive workshop service manual, presented in English, provides detailed guidance for the repair and maintenance of the Kawasaki Voyager Vulcan 1700 models from 2009 to 2012. Covering a vast array of systems from the engine, fuel, and transmission to the electrical, braking, and suspension components, this manual is an essential resource for owners and technicians. It includes routine and scheduled maintenance procedures, in-depth engine overhaul instructions, diagnostic troubleshooting guides, and specific technical data such as torque specifications and fluid capacities. The manual is designed to facilitate accurate diagnosis and repair, ensuring the longevity and optimal performance of the motorcycle. 🏷️ Basic Information Identification Make: Kawasaki Model: Voyager Vulcan 1700 Family: Vulcan Style: Full-size Touring Motorcycle Codes Engine Code Prefix: VNT700 👋 Introduction Market Position Segment: Premium Full-Size Touring Motorcycle Target Audience: Long-distance touring riders, cruiser enthusiasts seeking comfort and amenities. Competitive Analysis Competitors: Harley-Davidson Electra Glide, Honda Gold Wing, Indian Roadmaster. Key Features Touring Amenities: Large fairing with integrated windshield, ample storage (saddlebags, trunk), comfortable seating, cruise control. Engine Type: V-twin, liquid-cooled, fuel-injected for smooth power delivery. Drive System: Low-maintenance belt final drive. 📋 Manual Details Coverage Areas Model Years Covered: 2009, 2010, 2011, 2012 Regions Covered: Global (specifications may vary slightly by market) Page Count Total Pages: 792 Manual Type Type: Workshop Service Manual Purpose: Repair and Maintenance Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete internal and external engine components, including disassembly, inspection, assembly, and troubleshooting. Fuel System: Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, lines, and pressure regulation. Transmission: Clutch operation, gearbox components, shifting mechanism, and lubrication. Drivetrain: Final drive system (belt drive), belt tensioning, and related components. Electrical System: Ignition system, starting system, charging system (alternator, regulator/rectifier), battery, lighting, and all wiring diagrams. Brakes: Front and rear brake systems, including hydraulic components, ABS (if equipped), pads, rotors, and bleeding procedures. Suspension: Front forks (telescopic, air-assisted), rear shock absorber, springs, and adjustments. Steering: Handlebars, steering head bearings, and related components. Cooling System: Radiator, coolant, fan, hoses, and thermostat. Exhaust System: Exhaust pipes, mufflers, and heat shields. Bodywork And Chassis: Frame, fairings, saddlebags, windshield, seat, and mounting hardware. Diagnostic Troubleshooting: Extensive troubleshooting guides for various symptoms and fault codes. Procedures Included Routine Maintenance: Oil changes, filter replacements, air filter cleaning/replacement, spark plug service, and general inspections. Scheduled Maintenance: Detailed maintenance schedules and procedures for specific mileage or time intervals. Engine Overhaul: Complete engine disassembly, reassembly, and critical component specifications for rebuilds. Fuel System Service: Injector cleaning, fuel pressure testing, and component replacement. Brake Service: Brake pad replacement, caliper servicing, rotor inspection, and brake fluid flush/bleed. Suspension Adjustment: Fork oil changes, air pressure adjustments, and rear shock adjustments. Electrical Diagnostics: Wiring diagram interpretation, component testing, and troubleshooting electrical faults. Chassis Repair: Fairing repair, saddlebag mounting and repair, and chassis component replacement. Troubleshooting Guides: Systematic approaches to diagnosing and resolving common and uncommon issues. Technical Depth Depth: Comprehensive, covering all aspects from basic maintenance to full engine and transmission rebuilds. Diagnostic Capability: Advanced diagnostic procedures, including component testing and electrical troubleshooting. Specifications Detail: Detailed torque specifications, clearances, fluid capacities, and wear limits. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text-based PDF, allowing for easy keyword searching. Print Quality Quality: High-resolution scans suitable for clear printing. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, SOHC, V-twin Displacement: 1700cc (103.6 cubic inches) Bore X Stroke: 102.0 mm x 104.0 mm Cooling System: Liquid-cooled Valve Train: SOHC (Single Overhead Camshaft), 4 valves per cylinder Compression Ratio: 9.5:1 Performance Horsepower: Approx. 93 HP @ 6000 RPM (at crankshaft) Torque: Approx. 113 lb-ft (153 Nm) @ 3500 RPM (at crankshaft) Fuel System Fuel Delivery: Fuel Injection (FI) with dual 40mm throttle bodies Fuel Type: Unleaded gasoline, 87 octane or higher Fuel Tank Capacity: 5.3 US gallons (20.1 L) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh, sequential manual Clutch Type: Wet, multi-disc Final Drive: Positive engagement, continuously variable transmission (CVT) type, belt drive Features Overdrive Gears: Includes overdrive gears for relaxed highway cruising. 📐 Dimensions Exterior Overall Length: Approx. 103.7 inches (2635 mm) Overall Width: Approx. 39.2...
The Kawasaki Voyager Vulcan 1700 is a full-size touring motorcycle designed for long-distance travel, offering a premium experience for riders. Introduced for the 2009 model year and produced through 2012, this model exemplifies Kawasaki's legacy of building reliable and powerful V-twin cruisers. Key features include a large fairing with an integrated windshield for wind protection, spacious saddlebags for ample storage, and standard electronic cruise control to enhance rider comfort on extended journeys. Its liquid-cooled, 1700cc V-twin engine delivers robust power and torque, complemented by a smooth, low-maintenance belt final drive, making it a strong contender in the touring motorcycle segment.
This comprehensive workshop service manual, presented in English, provides detailed guidance for the repair and maintenance of the Kawasaki Voyager Vulcan 1700 models from 2009 to 2012. Covering a vast array of systems from the engine, fuel, and transmission to the electrical, braking, and suspension components, this manual is an essential resource for owners and technicians. It includes routine and scheduled maintenance procedures, in-depth engine overhaul instructions, diagnostic troubleshooting guides, and specific technical data such as torque specifications and fluid capacities. The manual is designed to facilitate accurate diagnosis and repair, ensuring the longevity and optimal performance of the motorcycle.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Voyager Vulcan 1700
Family:
Vulcan
Style:
Full-size Touring Motorcycle
Codes
Engine Code Prefix:
VNT700
👋 Introduction
Market Position
Segment:
Premium Full-Size Touring Motorcycle
Target Audience:
Long-distance touring riders, cruiser enthusiasts seeking comfort and amenities.
Competitive Analysis
Competitors:
Harley-Davidson Electra Glide, Honda Gold Wing, Indian Roadmaster.
Key Features
Touring Amenities:
Large fairing with integrated windshield, ample storage (saddlebags, trunk), comfortable seating, cruise control.
Engine Type:
V-twin, liquid-cooled, fuel-injected for smooth power delivery.
Drive System:
Low-maintenance belt final drive.
📋 Manual Details
Coverage Areas
Model Years Covered:
2009, 2010, 2011, 2012
Regions Covered:
Global (specifications may vary slightly by market)
Page Count
Total Pages:
792
Manual Type
Type:
Workshop Service Manual
Purpose:
Repair and Maintenance
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete internal and external engine components, including disassembly, inspection, assembly, and troubleshooting.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, lines, and pressure regulation.
Transmission:
Clutch operation, gearbox components, shifting mechanism, and lubrication.
Drivetrain:
Final drive system (belt drive), belt tensioning, and related components.
Electrical System:
Ignition system, starting system, charging system (alternator, regulator/rectifier), battery, lighting, and all wiring diagrams.
Brakes:
Front and rear brake systems, including hydraulic components, ABS (if equipped), pads, rotors, and bleeding procedures.
Suspension:
Front forks (telescopic, air-assisted), rear shock absorber, springs, and adjustments.
Steering:
Handlebars, steering head bearings, and related components.
Cooling System:
Radiator, coolant, fan, hoses, and thermostat.
Exhaust System:
Exhaust pipes, mufflers, and heat shields.
Bodywork And Chassis:
Frame, fairings, saddlebags, windshield, seat, and mounting hardware.
Diagnostic Troubleshooting:
Extensive troubleshooting guides for various symptoms and fault codes.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, air filter cleaning/replacement, spark plug service, and general inspections.
Scheduled Maintenance:
Detailed maintenance schedules and procedures for specific mileage or time intervals.
Engine Overhaul:
Complete engine disassembly, reassembly, and critical component specifications for rebuilds.
Fuel System Service:
Injector cleaning, fuel pressure testing, and component replacement.
Brake Service:
Brake pad replacement, caliper servicing, rotor inspection, and brake fluid flush/bleed.
Suspension Adjustment:
Fork oil changes, air pressure adjustments, and rear shock adjustments.
Electrical Diagnostics:
Wiring diagram interpretation, component testing, and troubleshooting electrical faults.
Chassis Repair:
Fairing repair, saddlebag mounting and repair, and chassis component replacement.
Troubleshooting Guides:
Systematic approaches to diagnosing and resolving common and uncommon issues.
Technical Depth
Depth:
Comprehensive, covering all aspects from basic maintenance to full engine and transmission rebuilds.
Diagnostic Capability:
Advanced diagnostic procedures, including component testing and electrical troubleshooting.
Specifications Detail:
Detailed torque specifications, clearances, fluid capacities, and wear limits.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely searchable text-based PDF, allowing for easy keyword searching.
Print Quality
Quality:
High-resolution scans suitable for clear printing.
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, SOHC, V-twin
Displacement:
1700cc (103.6 cubic inches)
Bore X Stroke:
102.0 mm x 104.0 mm
Cooling System:
Liquid-cooled
Valve Train:
SOHC (Single Overhead Camshaft), 4 valves per cylinder
Fuel Injection (FI) with dual 40mm throttle bodies
Fuel Type:
Unleaded gasoline, 87 octane or higher
Fuel Tank Capacity:
5.3 US gallons (20.1 L)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh, sequential manual
Clutch Type:
Wet, multi-disc
Final Drive:
Positive engagement, continuously variable transmission (CVT) type, belt drive
Features
Overdrive Gears:
Includes overdrive gears for relaxed highway cruising.
📐 Dimensions
Exterior
Overall Length:
Approx. 103.7 inches (2635 mm)
Overall Width:
Approx. 39.2 inches (995 mm)
Overall Height:
Approx. 57.7 inches (1465 mm)
Wheelbase:
Approx. 66.5 inches (1690 mm)
Ground Clearance:
Approx. 5.7 inches (145 mm)
Seat Height:
Approx. 28.7 inches (730 mm)
Weights
Dry Weight:
Approx. 796 lbs (361 kg)
Curb Weight:
Approx. 850.9 lbs (386 kg)
Maximum Payload:
Consult owner's manual or service manual for specific payload limits.
🛡️ Safety Features
Ratings
Safety Standards:
Compliance with relevant motorcycle safety standards for target markets.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) available on some models.
Lighting:
Halogen headlamp, LED tail/brake lights, turn signals.
Passive Features
Frame Construction:
Steel, double-cradle frame for stability.
Cruise Control:
Standard electronic cruise control for fatigue reduction on long rides.
💡 Technology Features
Infotainment
Audio System:
Integrated audio system with AM/FM radio, CD player, and compatibility for external audio devices (e.g., MP3 player). May include handlebar-mounted controls.
Display:
LCD display for audio information, clock, and other vehicle status indicators.
Driver Assistance
Cruise Control:
Electronic cruise control is a significant convenience feature for touring.
Connectivity
Auxiliary Input:
Auxiliary audio input jack for connecting external music players.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,700 miles (6,000 km) or 6 months, whichever comes first. Refer to manual for exact specification.
Air Filter Interval:
Inspect every 3,700 miles (6,000 km); clean or replace as needed. Refer to manual for exact specification.
Spark Plug Interval:
Replace every 7,500 miles (12,000 km). Refer to manual for exact specification.
Brake Fluid Interval:
Replace every 2 years. Refer to manual for exact specification.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or SH, API SJ or SL, or API SM. Kawasaki Genuine Oil recommended.
Engine Oil Capacity:
4.0 US qt (3.8 L) without filter change; 4.2 US qt (4.0 L) with filter change.
Showaease Suspension Fluid SS-10 or equivalent (check manual for specific weight).
Known Issues
Idle Control:
Some owners have reported occasional rough idling or stalling, potentially related to throttle body synchronization or electronic control issues, which this manual would help diagnose.
Electrical Connectors:
Corrosion in electrical connectors can sometimes lead to intermittent faults; regular inspection recommended.
Belt Drive Tension:
Maintaining correct belt tension is crucial for longevity and smooth operation; the manual provides the precise procedure.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long-standing reputation for building powerful, reliable motorcycles across various segments, including cruisers and touring bikes.
Model Evolution
Vulcan Lineage:
The Vulcan nameplate has been used by Kawasaki for its cruiser motorcycles since the late 1980s, evolving through various displacements and styles. The 1700 Voyager represents a significant step up in displacement and touring capability within the Vulcan family.
Production
Production Period:
The 1700 Voyager Vulcan platform was introduced in 2009, with this specific generation covering models through 2012. Later iterations continued with updates.
🏆 Awards & Recognition
Recognitions
Motorcycle Press:
While specific awards for the 2009-2012 models might not be widely documented, the Kawasaki Vulcan 1700 platform has consistently been recognized by motorcycle publications for its comfortable ride, strong V-twin power, and value proposition in the touring segment.