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Installation instructions for FC7 Forward Controls for Kawasaki Vulcan Classic 800 VN800B and Custom VN800A It is highly recommended that you use a thread lock compound such as Loctite bRAND on all threads to keep them from vibrating loose. Please read these instructions entirely before starting. This picture shows the components of the FC7. Parts will be referred to by the names & numbers shown here. If you are missing anything please email email@example.com. 1- Cotter Pin 2- M10-1.25x70 Socket Head Cap Screw (x2) 3- 3/8” Nut (x2) 4- 5/16”x7/8” Clevis Pin 5- 3/8-16x1.25” Button Head Cap Screw 6- 3/8-16x2” Button Head Cap Screw 7- Brake Cable Mount 8- Shifter Linkage 9- FC7-R 10- FC7-L 11- Brake Linkage 12- Brake Pedal Spacer 13- 1/2” x 3/8” Sleeve Bearing 14- 1.5” Spacer(x4) 15- 3/8” Zinc Washer 16- not used 17- 3/8” Nylon Washer (x2) 18- 5/16” Zinc Washer(x4) A1- BSM3 A2- #8-32x5/16 Screw A3- 1/4” Zinc Washer Note: If you are also installing the PDL4 Pedal Kit, please refer to the PDL4 Installation instructions. Brake side Loosen the brake cable retaining clip on the bottom of the frame, under the exhaust pipe.Loosen the brake rod adjusting nut to allow slack in the brake line. See picture A. Picture A Cut the wire ties holding the brake switch wire to the frame, and work a little slack loose. Remove the two bolts holding the foot rest bracket to the frame and tilt the entire assembly out toward you to allow access to the inside. See picture B. Picture B Remove the cotter pin, washer and clevis pin from the end of the brake cable attached to the brake arm. Slide the rubber end off of the brake cable. While holding the brake cable with your left hand pull the foot rest bracket forward with your right hand to line up internal wire of the brake cable with the slot in the brake cable mount and remove the cable. Use needle nose pliers to remove the spring from the brake light switch. Use a small screw driver to push in the tabs of the brake light switch and work it out of its mount. Remove the pedal return spring from the brake arm, then remove the bolt holding the arm and slide it off of the brake pedal spline....
For complete details on the full line of cruisers, see your dealer or visit kawasaki.com The cruising lifestyle is all about freedom and individual expression. Show your creativity with a host of Genuine Kawasaki Accessories designed just for your Vulcan ® cruiser. From custom-painted tanks and fenders to beautifully chromed exhausts, studded seats and from windshields to driving lights and touring gear, we’ve got you covered. Kawasaki designs accessories specifically for each cruiser, so you know they’ll bolt on perfectly the first time. We also build them to the same exacting standards that we build our Vulcan cruisers. Choose the accessories you want at the time of purchase and include them in your Vulcan motorcycle financing, or get them later and enjoy putting them on yourself. Either way, Genuine Kawasaki Accessories are covered by a factory warranty so you’re protected no matter where you ride. See your dealer for more information or check out Genuine Kawasaki Accessories at kawasaki.com. Light the road with dual halogen lights delivering 22,000 candlepower each. Each light is surrounded in a chrome-plated housing and matches the headlight design to give your Vulcan cruiser a factory-installed appearance. The windshield is formed of durable polycarbonate and is hard-coated to resist scratching. The simple side-mounted design allows for quick installation. Providing additional wind protection for the lower body are windshield lowers featuring chrome-plated mounting brackets and trim. The saddlebags offer genuine leather outer construction for that classic look and hidden quick-release buckles for ease of use. The molded back allows for sturdy mounting and
The Vulcan Classics present a problem since they have numerous obstructions that hang below frame level that can interfere with the CenterStand's operation. Proper location of the CenterStand is critical to safe operation. Please read these instructions carefully and have someone help you to hold the bike until you are comfortable performing the lift yourself. Lifting the 1500/1600 To lift the front wheel of the 1500 the CenterStand must push up on the engine cases. This is quite all right as the engine is strong enough and the CenterStand's rubber Frame Guard will protect it from damage. Position the CenterStand so that it will push on the engine in the flat area between the front two case bolts/ribs and push down on the handle to perform the lift. This area isn't perfectly flat but should provide a stable enough platform for light service or cleaning. Lifting the rear wheel is a little bit trickier and you want to make sure you get it right the first time since the oil filter is in the lifting area and placing the CenterStand wrong could damage it. Locate the two frame lugs that hang below the frame and position the CenterStand so that it contacts these lugs at their front edge (This can be tricky since they're small but I got used to it real quick). Lift the bike using the normal procedure, when the lift is complete and done correctly the CenterStand should be wedged in between the frame lugs and the engine/trans case. This is a very stable lift and the bike won't go anywhere.
CAUTION! We Strongly recommend that a qualified technician install this kit if you do not completely understand the instructions prior to the install. INCLUDED IN THE KIT: (1) Black Intake Backing Plate (1) Support Bracket (1) Manifold Gasket (1) Phillips Stainless Sensor Screw (1) 90° Hose Fitting (1) Straight Hose Fitting (1) ½” x10” Vac Hose (1) Performance Re-Usable Air Filter (3) Standoffs (one has a hex side) (3) ¼-20x¾” Black Flat Head Allen Screws (3) Set Screws (2 are ¼-20 and 1 is 6mm) (1 ea.) Chrome Mesh & xXx Cover (1) Black Cover Plate TOOLS REQUIRED: 4, 5, 6mm, 1/8” & 5/32” Allen Wrenches 10 & 12mm & 7/16” Sockets Pliers (Std. & Needle-nose) Phillips & Flat Screwdrivers ® Blue Loctite Factory Service Manual INSTRUCTIONS: Please read all directions before starting this install. If at any time you are unsure or do not understand these procedures, please call us at the shop, or email firstname.lastname@example.org for help. Although it is not required, the BAK may be easier to install after removing the fuel tank. Please make sure the vehicle is cool before starting your work.
This quick referenceguide will assist locating a desiredtopic or procedure. .Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table oi contents page. aRefer to the sectional table of contents for the exact pagesto locate the specific topic required, ... Service Manual system,or may be reproduced, storedin a retrieval All rightsreserved. No partsof this publication photocopying, or recording otherin any form or by any means,electronicmechanical transmitted Products of wise, without the prior written permission Ouality AssuranceDepartment/Consumer Ltd., Japan. Group/Kawasaki HeavyIndustries, althoughevery or in No liabilitycan be accepted any inaccuracies omissions this publication, for possiblecare has beentakento make it as completeand accurateas possible. The right is reserved make changesat any time without prior notice and without incurringan to previously. Seeyour Motorcycle dealer to makesuch changes productsmanufactured to obligation incorporated information productimprovements after this publication. for the latest on at available...