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1. Page 3 e Drive the pulley shaft out from the pulley side left side then remove the pulley shaft with the bearing from the right side e Insert the new pulley shaft A and new bearing B from the right side r E 4 z e o iL a i pem J p a e Drive the bearing into the crankcase until it seats special Tool Bearing Driver A 57001 1684 Steering Stem Bearing Driver B 57001 137 NOTE Bearing Driver P N 57001 1684 is a Special Tool required for this FDM Your Dealership will be reimbursed the cost of the tool If shaft replacement is necessary contact the Product Support Hot Line to release a shaft and tool Install the pulley shaft bearing retainers and SCrews Torque Bearing retainer screws 61 in lb 6 9 N m 0 7 kgf m Install the transfer gear and washer Replace the transfer gear nut with a new one Apply molyodenum disulfide oil to the nut thread and seating surfaces of the washer and nut and tighten to the proper torque Torque Transfer Gear Nut Pulley Shaft 58 fl lb 78 N m 8 0 kgf m Special Tool Gear Holder 57001 1574 Be sure that the spring A and pin B as well as the dowel pins C are in position Replace the inner transmission cover gasket with a new one Apply Sealant to the grommet for the gear position switch lead in the inner transmission cover sealant Kawasaki Bond 92104 0004 Three Bond 1B1211F Tighten the inne
2. NOTE o Repair verification is an essential part of the repair procedure Along with the physical repair verification mark check VSI Vehicle Service Inguiry in K Dealer for other possible repair campaigns for eligible units Page 6 VULCAN 2000 ENGINE PULLEY WEAR FACTORY DIRECTED MODIFICATION Dear Kawasaki Vulcan 2000 Owner The reason for this notice On eligible units the splines on the engine pulley and or pulley shaft may be worn due to the type of assembly lubricant used during assembly This can result in the engine pulley mounting nut not applying enough clamping force to properly hold the pulley in place and creating abnormal wear on the splines of the pulley and or pulley shaft The worn splines may cause abnormal noise and the vehicle may not accelerate smoothly Our records indicate that you have bought one of these units What Kawasaki and your dealer will do Kawasaki has initiated a Factory Directed Modification campaign to repair all affected units The repair will consist of 1 removing the engine pulley to inspect the pulley and shaft splines replacing the pulley and or shaft if they are worn and 2 applying molybdenum grease to the pulley shaft threads and engine pulley mounting nut seating surface during installation and tightening the nut to the proper torque This repair will be made by an authorized Kawasaki motorcycle dealer at no charge Repair time will differ depending on the results of the inspection T
3. and engine pulley mounting nut seating surface during installation and tightening the nut Notify Registered Owners Kawasaki is sending a FDM letter to all registered owners of eligible units A copy of the letter is printed on the last page of this bulletin Repair Eligible Units Inspect repair all eligible units including sold units in the field and unsold units in your dealership inventory prior to delivery to the retail purchaser It is the obligation of authorized Kawasaki retail Dealers to repair eligible units in Dealer s possession prior to retail sale Failure to comply with this obligation to repair all units eligible for Recall or FDM campaigns by the Dealer constitutes a breach of the Dealer Sales and Service Agreement Refer to Service Policies bulletin SP 05 01 Refer to the Repair Procedure section of the bulletin for details NOTE o Ifyou fail to submit a Warranty Claim for a new unit that is subsequently sold and registered the new owner will receive the FDM letter requesting the return of the vehicle to you for repair Submit Product Registration Submit the product registration to Kawasaki via K Dealer immediately after retail sale of any eligible unit Be sure to supply the correct customer name and mailing address Kawasaki uses the product registration information for customer notification Also if you know that the customer has moved please submit a Customer Update via K Dealer ey ade Kawasaki E
4. to a new pulley shaft O ring C SAU eC BE and install the collar A and O ring C on the Bearing Ball 92045 1190 Paley 92210 0138 Oo S 92055 0006 67001508 NOTE o To order the pulley shaft P N 13107 0108 or bearing driver P N 57001 1684 you must call the Product Support Hot Line Page 5 This is a Factory Directed Modification Repair is authorized regardless of ownership or warranty status Repairs MUST BE PERFORMED IMMEDIATELY ON ALL ELIGIBLE UNITS in the field and during initial preparation See the Warranty Policies and Procedures Manual claim type 3 information for detailed instructions when Submitting the Warranty Claim NOTE o WORN PULLEY SHAFT PARTS MUST BE RETURNED CLAIMS WILL NOT BE PAID IF THE PULLEY AND OR SHAFT SHOWS NO SIGNS OF DAMAGE O The failure rate is expected to be extremely low Return parts to the following address Kawasaki Motors Corp U S A ATTN Warranty Administration MC 06 07 9950 Jeronimo Rd Irvine CA 92618 Warranty Information Only Engine Engine Pulley Pulley Only amp Pulley Shaft Number Oty 0 7 hr 3 8 hr Additional Eats P 13107 0108 67002014 92055 1308 __ 67082020 L 11061 0017 11061 0018 o ee qty 2 92045 1190 __ 92210 0138 __ 92055 0006 __ 92055 1146 670D1508_ 570011684 _ NEW After repair or inspection make a small punch mark after the engine number as shown cal Se VHS ia l A
5. DGE OF Let the good times roll POWER PERFORMANCE EXHILARATION Refer to the appropriate sections of the service Manual for information and procedures related to parts removal and installation MODEL SERVICE MANUAL PART NUMBER VN2000A 99924 1320 01 thru 04 Inspection of the Engine Pulley pulley Shaft e Remove the engine pulley cover e Completely loosen the drive belt e Flatten the bent washer holding the engine pulley mounting nut e Hold the engine pulley A with the pulley holder B and remove the pulley mounting nut C Special tools Pulley Holder 57001 1572 or Rotor Holder 57001 1672 Grip 57001 1591 e Remove the engine pulley from the pulley shaft and inspect the splines on the pulley and shaft to determine if they are worn es GOOD PULLEY WORN PULLEY If the pulley and shaft are not worn follow the instructions in Installation of Engine Pulley If only the engine pulley splines are worn replace the pulley following the instructions in Installation of Engine Pulley If the pulley shaft is also worn replace it following the instructions in Replacement of the Pulley Shaft GOOD PULLEY SHAFT SCUFFING Installation of the Engine Pulley e Align the splines inside the engine pulley with those on the pulley shaft and mount the pulley e Replace the pulley washer with a new one e Apply molyodenum grease to the threads of the pulley shaft and seating surface of
6. REPLACES Please discard MC 06 07 dated June 27 2006 MC 06 07 Date July 28 2006 First Issued June 27 2006 Page 1 of 7 MODEL 2004 2005 VULCAN 2000 VN2000 A1 L A2 L TITLE ENGINE PULLEY WEAR FACTORY DIRECTED MODIFICATION IMMEDIATE INSPECTION REPAIR ONLY AS REQUIRED Eligible Units Model Vehicle Identification Number Range VN2000 A1 L JKBVNMA1 4A000032 thru 004668 VN2000 A2 L JKBVNMA1 5A006008 thru 006195 Please check VSI Vehicle Service Inquiry in K Dealer for other possible repair campaigns for eligible units Kawasaki will repair some units prior to you receiving them Repair can be verified using VSI or by the Repair Verification See Repair Verification section for details On eligible units the splines on the engine pulley and or pulley shaft may be worn due to the type of assembly lubricant used during assembly This can result in the engine pulley mounting nut not applying enough clamping force to properly hold the pulley in place and creating abnormal wear on the splines of the pulley and or pulley shaft The worn splines may cause abnormal noise and the vehicle may not accelerate smoothly Initiate Campaign Kawasaki has initiated a FDM campaign to inspect repair all eligible units The repair consists of 1 removing the engine pulley to inspect the pulley and shaft splines replacing the pulley and or shaft if they are worn and 2 applying molyodenum grease to the pulley shaft threads
7. he actual repair will take up to 4 hours but may take longer due to scheduling at the dealership and the time needed to obtain required parts Please call your Kawasaki motorcycle dealer to schedule an appointment and take this letter with you at that time If you need help If you have questions or concerns that your dealer is not able to resolve please contact Kawasaki s Consumer Services Department Kawasaki Motors Corp U S A ATTN Consumer Services Department PO Box 25252 Santa Ana California 92799 5252 949 460 5688 between 8 30 a m and 4 45 p m PT Monday through Friday If you received this notice in error Our records indicate you are the current owner of the Vulcan 2000 described in this letter If you no longer have the vehicle described in this letter or if it has been repaired please help us to update our records by calling Kawasaki toll free at 866 802 9381 between 8 30 a m and 4 45 p m PT Monday through Friday We are sorry for any inconvenience but we have taken this action in your best interest and continued satisfaction with your Kawasaki motorcycle Please contact your dealer if you have any questions Sincerely KAWASAKI MOTORS CORP U S A Page 7
8. r transmission cover bolts in the order shown below to the proper torque then torque the No 1 amp 2 bolts again Torque Inner Transmission Cover Bolts 104 in lb 12 N m 1 2 kgf m e Apply grease to new O rings and install the e Install the engine pulley following the nstallation water pipes tightening the bolts to the proper of Engine Pulley instructions pine e Install the mufflers Torque Water Pipe Bolts 87 in lb 9 8 N m e Refill the engine oil and coolant 1 0 kgf m e Be sure the dowel pins A are in place and NOTE position a new outer transmission cover o Reference service bulletin MC 04 06 for proper gasket Vulcan 2000 engine oil level checking procedures The following parts will be required for repair ONLY ORDER PARTS AS NEEDED FOR FAILED UNITS IN YOUR DEALERSHIP INSPECTION ONLY Part Number 92200 0017 e Apply grease to a new O ring for the oil pipe in the outer transmission cover then install the REPLACE ENGINE PULLEY ONLY outer transmission cover and tighten the bolts in the order shown along with the oil pipe bolt to the proper torque then torque them again Cotter Pin 550D4035 ES Pulley Belt 49079 0014 REPLACE ENGINE PULLEY AND SHAFT Torque Outer Transmission Cover Bolts 104 670D2014 ieee Nai ee 92055 1308 Oil Pipe Bolt 87 in lb 9 8 N m 1 0 kgf m 67082020 e Connect the gear position sensor lead oe connector 11061 0018 e Apply grease
9. the engine pulley mounting nut then tighten the nut APPLY MOLYBDENUM GREASE Page 2 Torque Engine Pulley Mounting Nut 130 ft e Unscrew the bolts A and remove the water lb 177 N m 18 kgf m pipe B Special Tools Pulley Holder 57001 1572 or 57001 1672 Grip 57001 1591 NOTE o Rotor holder and grip P N 57001 1672 57001 1591 are a part of the Kawasaki Essential Too Program and are shipping to Dealers the week of June 26 2006 See bulletin ST 06 07 e Bend one side of the washer over the nut e Adjust drive belt deflection and use a new cotter pin after tightening the rear axle nut e Remove the bolts C and pull down the rear brake master cylinder D with the hoses e Install the engine pulley cover Replacement of the Pulley Shaft e Drain the engine oil and coolant attached e Remove mufflers e Remove the inner transmission bolts E and R inner transmission cover F e Remove Oil Level Gauge Oil Filler Cap A e Loosen the transfer gear nut A on the pulley shaft f Oil Pipe Bolt B Outer Transmission Cover Bolts C e Remove the outer transmission cover D with the oil pipe E Ic m i BIOAB209A P Special Tool Gear Holder B 57001 1574 e Remove the transfer gear nut and transfer gear C e Remove the pulley shaft bearing retainer screws and bearing retainers e Disconnect the gear position sensor lead connector

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