SERVICE FACTORY DIRECTED MODIFICATION MC IMMEDIATE INSPECTION REPAIR ONLY AS REQUIRED ENGINE PULLEY WEAR

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1 SERVICE REPLACES: Please discard MC dated June 27, 2006 MODEL: VULCAN 2000 (VN2000-A1/L-A2/L) MC Date: July 28, 2006 First Issued: June 27, 2006 Page 1 f 7 TITLE: ENGINE PULLEY WEAR FACTORY DIRECTED MODIFICATION IMMEDIATE INSPECTION REPAIR ONLY AS REQUIRED Eligibility Eligible Units Mdel Vehicle Identificatin Number Range VN2000-A1/L JKBVNMA1 4A thru VN2000-A2/L JKBVNMA1 5A thru Please check VSI (Vehicle Service Inquiry) in K-Dealer fr ther pssible repair campaigns fr eligible units. Kawasaki will repair sme units prir t yu receiving them. Repair can be verified using VSI r by the Repair Verificatin. See Repair Verificatin sectin fr details. Subject On eligible units, the splines n the engine pulley and/r pulley shaft may be wrn due t the type f assembly lubricant used during assembly. This can result in the engine pulley munting nut nt applying enugh clamping frce t prperly hld the pulley in place and creating abnrmal wear n the splines f the pulley and/r pulley shaft. The wrn splines may cause abnrmal nise and the vehicle may nt accelerate smthly. Kawasaki Actin Initiate Campaign: Kawasaki has initiated a FDM campaign t inspect/repair all eligible units. The repair cnsists f 1) remving the engine pulley t inspect the pulley and shaft splines, replacing the pulley and/r shaft if they are wrn, and 2) applying mlybdenum grease t the pulley shaft threads and engine pulley munting nut seating surface during installatin and tightening the nut. Ntify Registered Owners: Kawasaki is sending a FDM letter t all registered wners f eligible units. A cpy f the letter is printed n the last page f this bulletin. Dealer Actin Repair Eligible Units: Inspect/repair all eligible units including sld units in the field and unsld units in yur dealership inventry prir t delivery t the retail purchaser. It is the bligatin f authrized Kawasaki retail Dealers t repair eligible units in Dealer s pssessin prir t retail sale. Failure t cmply with this bligatin t repair all units eligible fr Recall r FDM campaigns by the Dealer cnstitutes a breach f the Dealer Sales and Service Agreement. Refer t Service Plicies bulletin SP Refer t the Repair Prcedure sectin f the bulletin fr details. If yu fail t submit a Warranty Claim fr a new unit that is subsequently sld and registered, the new wner will receive the FDM letter requesting the return f the vehicle t yu fr repair. Submit Prduct Registratin: Submit the prduct registratin t Kawasaki via K-Dealer immediately after retail sale f any eligible unit. Be sure t supply the crrect custmer name and mailing address. Kawasaki uses the prduct registratin infrmatin fr custmer ntificatin. Als, if yu knw that the custmer has mved, please submit a Custmer Update via K-Dealer. File behind the MC tab in yur Kawasaki Service and Warranty binder 2006, Kawasaki Mtrs Crp., U.S.A.

2 Repair Prcedure Refer t the apprpriate sectins f the Service Manual fr infrmatin and prcedures related t parts remval and installatin. MODEL SERVICE MANUAL PART NUMBER VN2000A thru -04 GOOD PULLEY SHAFT Inspectin f the Engine Pulley/pulley Shaft Remve the engine pulley cver. Cmpletely lsen the drive belt Flatten the bent washer hlding the engine pulley munting nut. Hld the engine pulley (A) with the pulley hlder (B) and remve the pulley munting nut (C). SCUFFING TEETH SIDE WEAR Special tls Pulley Hlder: (r Rtr Hlder: ) Grip: Remve the engine pulley frm the pulley shaft and inspect the splines n the pulley and shaft t determine if they are wrn. Installatin f the Engine Pulley Align the splines inside the engine pulley with thse n the pulley shaft and munt the pulley. Replace the pulley washer with a new ne. Apply mlybdenum grease t the threads f the pulley shaft and seating surface f the engine pulley munting nut, then tighten the nut. GOOD PULLEY WORN PULLEY If the pulley and shaft are nt wrn, fllw the instructins in Installatin f Engine Pulley. If nly the engine pulley splines are wrn, replace the pulley fllwing the instructins in Installatin f Engine Pulley. If the pulley shaft is als wrn, replace it fllwing the instructins in Replacement f the Pulley Shaft. APPLY MOLYBDENUM GREASE Page 2

3 Trque Engine Pulley Munting Nut: 130 ft.- lb. (177 N-m, 18 kgf-m) Special Tls Pulley Hlder: (r ) Grip: Rtr hlder and grip (P/N , ) are a part f the Kawasaki Essential Tl Prgram and are shipping t Dealers the week f June 26, See bulletin ST Bend ne side f the washer ver the nut. Adjust drive belt deflectin, and use a new ctter pin after tightening the rear axle nut. Install the engine pulley cver. Replacement f the Pulley Shaft Drain the engine il and clant. Remve mufflers. Remve: Oil Level Gauge/Oil Filler Cap (A) Oil Pipe Blt (B) Outer Transmissin Cver Blts (C) Remve the uter transmissin cver (D) with the il pipe (E). Unscrew the blts (A) and remve the water pipe (B). Remve the blts (C) and pull dwn the rear brake master cylinder (D) with the hses attached. Remve the inner transmissin blts (E) and inner transmissin cver (F). Lsen the transfer gear nut (A) n the pulley shaft. Discnnect the gear psitin sensr lead cnnectr. Special Tl Gear Hlder (B): Remve the transfer gear nut and transfer gear (C). Remve the pulley shaft bearing retainer screws and bearing retainers. PULLEY SHAFT BEARING RETAINER SCREWS Page 3

4 Drive the pulley shaft ut frm the pulley side (left side), then remve the pulley shaft with the bearing frm the right side. Remve the cllar (A) and O-ring (B). A B Bearing Driver (P/N ) is a Special Tl required fr this FDM. Yur Dealership will be reimbursed the cst f the tl. If shaft replacement is necessary, cntact the Prduct Supprt Ht Line t release a shaft and tl. Install the pulley shaft bearing retainers and screws. Trque 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 ne. Apply mlybdenum disulfide il t the nut thread and seating surfaces f the washer and nut and tighten t the prper trque. Trque Transfer Gear Nut (Pulley Shaft): 58 fl.-lb. (78 N-m, 8.0 kgf-m) Special Tl Gear Hlder: Be sure that the spring (A) and pin (B), as well as the dwel pins (C), are in psitin. Insert the new pulley shaft (A) and new bearing (B) frm the right side. B A Drive the bearing int the crankcase until it seats. Replace the inner transmissin cver gasket with a new ne. Apply Sealant t the grmmet fr the gear psitin switch lead in the inner transmissin cver. Sealant Kawasaki Bnd: (Three Bnd TB1211F) Tighten the inner transmissin cver blts in the rder shwn belw t the prper trque, then trque the N. 1 & 2 blts again. A B Special Tl Bearing Driver (A): Steering Stem Bearing Driver (B) Page 4 Trque Inner Transmissin Cver Blts: 104 in.-lb. (12 N-m, 1.2 kgf-m)

5 Apply grease t new O-rings and install the water pipes, tightening the blts t the prper trque. Trque Water Pipe Blts: 87 in.-lb. (9.8 N-m, 1.0 kgf-m) Be sure the dwel pins (A) are in place and psitin a new uter transmissin cver gasket. Install the engine pulley fllwing the Installatin f Engine Pulley instructins. Install the mufflers. Refill the engine il and clant. Reference service bulletin MC fr prper Vulcan 2000 engine il level checking prcedures. Parts Infrmatin The fllwing parts will be required fr repair. ONLY ORDER PARTS AS NEEDED FOR FAILED UNITS IN YOUR DEALERSHIP. INSPECTION ONLY Apply grease t a new O-ring fr the il pipe in the uter transmissin cver, then install the uter transmissin cver and tighten the blts in the rder shwn, alng with the il pipe blt, t the prper trque, then trque them again. Trque Outer Transmissin Cver Blts 104 in.-lb. (12 N-m, 1.2 kgf-m) Oil Pipe Blt: 87 in.-lb. (9.8 N-m, 1.0 kgf-m) Cnnect the gear psitin sensr lead cnnectr. Apply grease t a new pulley shaft O-ring (C) and install the cllar (A) and O-ring (C) n the pulley shaft (B). Descriptin Part Number Qty Washer Ctter Pin 550D REPLACE ENGINE PULLEY ONLY Descriptin Part Number Qty Washer Ctter Pin 550D Pulley Belt REPLACE ENGINE PULLEY AND SHAFT Descriptin Part Number Qty Washer Ctter Pin 550D Pulley Belt Shaft Pulley Bearing Driver O-Ring 670D O-Ring O-Ring 670B Gasket, Trans Gasket, Trans Exhaust Pipe Gasket Bearing, Ball Nut Fitting Fitting O-Ring 670D NEW T rder the pulley shaft (P/N ) r bearing driver (P/N ), yu must call the Prduct Supprt Ht Line. Page 5

6 Warranty Infrmatin This is a Factry Directed Mdificatin. Repair is authrized regardless f wnership r warranty status. Repairs MUST BE PERFORMED IMMEDIATELY ON ALL ELIGIBLE UNITS in the field and during initial preparatin. See the Warranty Plicies and Prcedures Manual (claim type 3 infrmatin) fr detailed instructins when submitting the Warranty Claim. Repair Verificatin After repair r inspectin, make a small punch mark after the engine number as shwn. WORN PULLEY/SHAFT PARTS MUST BE RETURNED CLAIMS WILL NOT BE PAID IF THE PULLEY AND/OR SHAFT SHOWS NO SIGNS OF DAMAGE. The failure rate is expected t be extremely lw. Return parts t the fllwing address: Kawasaki Mtrs Crp., U.S.A. ATTN: Warranty Administratin, MC Jernim Rd. Irvine, CA Warranty Infrmatin Item Inspectin Only Replace Engine Pulley Only Replace Engine Pulley & Pulley Shaft Claim Type Jb Cde Causal Part Number Causal Part WASHER Qty 1 Flat Rate Time 0.7 hr 0.7 hr 3.8 hr Failure Date Same as Repair Date Additinal Parts 550D D D D B (qty. 2) D NEW PUNCH MARK HERE Repair verificatin is an essential part f the repair prcedure. Alng with the physical repair verificatin mark, check VSI (Vehicle Service Inquiry) in K-Dealer fr ther pssible repair campaigns fr eligible units. Page 6

7 VULCAN 2000 ENGINE PULLEY WEAR FACTORY DIRECTED MODIFICATION Dear Kawasaki Vulcan 2000 Owner: The reasn fr this ntice: On eligible units, the splines n the engine pulley and/r pulley shaft may be wrn due t the type f assembly lubricant used during assembly. This can result in the engine pulley munting nut nt applying enugh clamping frce t prperly hld the pulley in place and creating abnrmal wear n the splines f the pulley and/r pulley shaft. The wrn splines may cause abnrmal nise and the vehicle may nt accelerate smthly. Our recrds indicate that yu have bught ne f these units. What Kawasaki and yur dealer will d: Kawasaki has initiated a Factry Directed Mdificatin campaign t repair all affected units. The repair will cnsist f 1) remving the engine pulley t inspect the pulley and shaft splines, replacing the pulley and/r shaft if they are wrn, and 2) applying mlybdenum grease t the pulley shaft threads and engine pulley munting nut seating surface during installatin and tightening the nut t the prper trque. This repair will be made by an authrized Kawasaki mtrcycle dealer at n charge. Repair time will differ depending n the results f the inspectin. The actual repair will take up t 4 hurs, but may take lnger due t scheduling at the dealership and the time needed t btain required parts. Please call yur Kawasaki mtrcycle dealer t schedule an appintment and take this letter with yu at that time. If yu need help: If yu have questins r cncerns that yur dealer is nt able t reslve, please cntact Kawasaki s Cnsumer Services Department: Kawasaki Mtrs Crp., U.S.A. ATTN: Cnsumer Services Department P.O. Bx Santa Ana, Califrnia (949) between 8:30 a.m. and 4:45 p.m. PT Mnday thrugh Friday. If yu received this ntice in errr: Our recrds indicate yu are the current wner f the Vulcan 2000 described in this letter. If yu n lnger have the vehicle described in this letter, r if it has been repaired, please help us t update ur recrds by calling Kawasaki tll free at (866) between 8:30 a.m. and 4:45 p.m. PT Mnday thrugh Friday. We are srry fr any incnvenience, but we have taken this actin in yur best interest and cntinued satisfactin with yur Kawasaki mtrcycle. Please cntact yur dealer if yu have any questins. Sincerely, KAWASAKI MOTORS CORP., U.S.A. Page 7

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