Top 20 2002 kawasaki VN 1500 Vulcan Classic Questions & Answers


How many miles?? The needle jet/jet needle (brass kit) may need replacing ...they wear out due to vibration and cause the spark plugs to turn black, get poor milage, and then "carbon foul".
Try running it without the air filter for a few miles.. see if that makes it run better. If so, I would replace the air filter and put a new brass kit in the carburetor.
You can try moving the CLIP on the needle UP to the second to the top position, OR the top position..that will lean out the mixture/carburetor.

Kawasaki Vulcan 1500 Classic 1996 2004 Service Repair Maintenance

2002 kawasaki VN... | 56 views | 0 helpful votes


Hi, Anonymous if you have changed your fuel delivery system, air filter size or flow rate, mufflers or exhaust system or a significant change in altitude your carburetors need re-tuning and if your fuel system (gas tank, filters, fuel valve and carburetor) is contaminated with ethanol sludge, varnish, rust, dirt, water etc. or your bike has been sitting for months or years without running these components must be "PROPERLY" cleaned and reassembled "CORRECTLY" before any adjustments can be made. Tuning your carburetor is fairly simple once you understand the basic principals. You engine is a simple airbox sucking air in and blowing it out, it is finely tuned at the factory for maximum performance once you upset that delicate balance by changing air filters, camshafts or exhaust systems your performance may go down the and the engine may run poorly, you need to compensate the air-fuel mixture in the carburetor in order for the engine to run smoothly and at peak performance. If you are running multi carburetors you need to sync them first and make sure your air cleaner element is clean and dry for paper elements or lightly oiled for foam and meshed elements and properly installed. Here is how and where you compensate trouble: "TIP" if your engine "BOGS" your not getting enough fuel.
1. Closed to 1/8 throttle is managed by the air screw and pilot/slow jet.
2. 1/8 to 1/4 throttle is managed by the air-screw, pilot/slow jet, and throttle slide.
3. 1/4 to 1/2 throttle is managed by the throttle slide and jet needle.
4. 1/2 to 3/4 throttle is managed by the jet needle, needle jet, main jet, and air jet.
5. 3/4 to wide open throttle is managed by the main jet and air jet.
6. Wide open throttle is managed by the main jet.
If you are running lean, spark plug electrode color is white, engine runs hot and feels like it is starving for fuel you need to go up on the jet size or move the c-clip down one notch. If you are running rich, spark plug color is black or dark gray, the engine runs cool, and bogs down when accelerating you need to go down on jet size or move the c-clip up one notch. When your carburetor is properly tuned for maximum performance your spark plug electrode will be a light tan color like coffee with cream. If you prefer fuel economy over performance you can go down on main jet sizes until a satisfactory level of lower performance is acceptable versus MPH, your spark plug color will be whiter and your engine will run warmer. These tuning adjustments will only make improvements if your intake and exhaust system have no air leaks or sealing issues and the entire electrical system is in proper working order and you have no mechanical issues.
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
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2002 kawasaki VN... | 256 views | 0 helpful votes


ok take the clutch maste cylinder cap off on the handlebars,get a ball of tissue and gently put it into the fluid it will soak it up,repeat this until its dry in there but make sure you dont drip it anywhere or it will damage your paintwork,also do NOT pull the lever in yet,then fill it 3/4 up with new fluid ,then put a spanner on the bleed nipple on the clutch slave cylinder on the left hand side of the engine ,then put a clear pipe onto the end of the nipple and get a small coke bottle or similar and make a hole in the cap which is a snug fit for the pipe push the pipe in then loosen the cap slightly so it can breathe,then gently pull the lever in and hold it in ,then undo the nipple until some fluid comes into the pipe then do it back up ,let the lever out and pull it back in and loosen the nipple again holding the lever again as before,repeat this until the fluid runs clean ,Make sure the fluid does NOT run out during this as you will be back at square one ,if easier get someone to keep an eye on the level and top it up when needed.good luck Adam.

2002 kawasaki VN... | 130 views | 0 helpful votes


Hi Zack, I am sorry you can't find the first and best tool you ever bought for your Kawasaki but despair not for a mere $10 you can download another one. For more information about your issue, please visit the websites below. Good luck and have a nice day.
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2002 kawasaki VN... | 55 views | 0 helpful votes


wire them to the acc side of the key switch

2002 kawasaki VN... | 40 views | 0 helpful votes


which red light? there are several there. what is printed on it?

2002 kawasaki VN... | 101 views | 0 helpful votes


Solenoid is sticking, age,heat, dirt etc on the solenoid shaft makes it stick. It may be possible to replace the solenoid assy, but easier to replace the unit as a whole motor and solenoid, it may also be non serviceable. Make sure you did not loose any teeth on the flywheel. it will make a deadspot, motor spins free without engaging the teeth. And if it catches one while spinning it will break another one off. Good Luck

2002 kawasaki VN... | 153 views | 0 helpful votes


Hi, Anonymous for this scenario you will need your service manual that has a wiring diagram in the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2002 kawasaki VN... | 130 views | 0 helpful votes


Hi, Anonymous for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2002 kawasaki VN... | 180 views | 0 helpful votes


Hi, Anonymous and the usual suspects are:
1. Clutch cable adjusted too tight.
2. Pressure plate center screw adjusted too tight
3. A broken clutch rod.
4. Slave cylinder piston stuck.
5. Clutch plate missing from the clutch pack.
6. Clutch plates have worn past minimum specifications.
7. Clutch plates crystallized due to incompatible oil.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2002 kawasaki VN... | 69 views | 0 helpful votes


Hi, Anonymous for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2002 kawasaki VN... | 140 views | 0 helpful votes


Hi, Anonymous for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
http://www.kawasakimotorcycle.org/forum/kawasaki-cruisers/59865-how-much-oil-1500-classic.html
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2002 kawasaki VN... | 115 views | 0 helpful votes


Hi, Anonymous and the usual suspects are:
1. Clutch not adjusted properly.
2. Primary chaincase overfilled with lubricant.
3. Corners wore off shifter clutch dogs.
4. Shifter return spring bent or broken.
5. Bent shifter rod.
6. A loose shift lever on shifter shaft.
7. Shifter forks sprung.
8. Shifter pawl needs adjusting.
9. Heel/toe shifter coming in contact with the floorboard.
10. Transmission oil too heavy.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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http://www.kawasakimotorcycle.org/forum/kawasaki-cruisers/103739-vulcan-1500-shifting-problem.html
Kawasaki Vulcan 1500 Classic Fi Service Manual
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2002 Kawasaki Vulcan 1500 Classic Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2002 kawasaki VN... | 38 views | 0 helpful votes


Hi, Anonymous the vast majority of service, parts fiche, and owners manuals on the internet are "FREE" to download and all service manuals contain wiring diagrams in the back pages. The rest usually charge a modest fee of $15 and there is a handful of obscure, rare, obsolete, and very old models that are no longer or never were available and some were never printed in English. The Indian and Philippine markets are usually in E-book format only, for these rare occasions I shall look on eBay and find the cheapest one available. Most of the manuals will cover your exact make, model, and year otherwise one will be provided that comes as close as possible to your bike and will have most of the same info that an exact manual would have. If there is no $ sign after the manual link it is free to download.
To download your manual for viewing or printing please click on the blue links below. Good luck and have a wonderful day
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2002 kawasaki VN... | 37 views | 0 helpful votes


Hi, Anonymous if your headlight is not working, intermittent, only one beam works, keeps burning out, blinking, dim or surges from bright to dim to bright the first thing you need to check is the headlight bulb for damaged filaments then check your light circuit fuse, then check your head light bulb socket ground wire for a clean tight connection, that being said the usual suspects are:
1. Faulty ground or power supply wire to headlight bulb socket.
2. Worn down solder contacts or loose fit of the bulb base in the socket due to vibration.
3. Worn, chafed, or broken wires in the light circuit.
4. Corroded, broken, or loose pins/sockets in wire connectors.
5. Faulty hi/low beam switch.
6. Faulty ignition switch.
7. Fuse is good but no continuity on both sides.
8. Faulty headlight relay.
9. Faulty wiring between battery positive and headlight bulb socket.
10. Weak charging alternator/generator/lighting coil
11. Faulty voltage regulator/rectifier ground or overcharging.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2002 kawasaki VN... | 67 views | 0 helpful votes


Hi, Anonymous for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
http://www.kawasakimotorcycle.org/forum/kawasaki-cruisers/152752-how-change-transmission-oil-2003-vulcan-1600-a.html
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2002 Kawasaki Vulcan 1500 Classic Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2002 kawasaki VN... | 25 views | 0 helpful votes


Hi, Anonymous it's called "WET SUMPING" if left sitting for weeks or months will eventually let the oil tank contents drain pass the oil pump check ball and fill up the bottom end of the crankcase when the bike is started the excess oil will gush out of the breather vent and if routed to the air cleaner will also flood the filter. This messy condition will continue until the bottom end is forcibly emptied by the flywheels or manually drained if there is a plug. There are 3 options you may want to consider:
1. Drain the oil tank before storing the bike.
2. Replace check ball and resurface seat in the oil pump.
3. Install inline ball valve shut off in the feed line to the pump.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Crankcase breather hose Kawasaki Vulcan Forum Vulcan Forums http://www.kawasakimotorcycle.org/forum/kawasaki-cruisers/12214-crankcase-breather-valve-marbelized-breather-hose.html
Kawasaki Vulcan 1500 Classic Fi Service Manual
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2002 Kawasaki Vulcan 1500 Classic Owner Manual

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

2002 kawasaki VN... | 33 views | 0 helpful votes


Many bikes have a fuel overflow at the fill opening at the tank. So excess fuel can drain to the ground. This is done with a tube that comes from the rear of the tank (close to the seat) and routes down under the frame to the ground. If that tube is routed to your battery box then you have a safety issue. Make sure you do not have this drain tube/hose routed to your battery box. I am sure you don't want a fire under your seat.

2002 kawasaki VN... | 75 views | 0 helpful votes


check the routing of the overflow pipe from the tank for leaks a photo would help

2002 kawasaki VN... | 69 views | 0 helpful votes

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