Kawasaki Vulcan 1600 Classic Nomad Tourer VN1600
WORKSHOP MANUAL - REPAIR MANUAL - WIRING DIAGRAMS
KAWASKI VULCAN 1600 CLASSIC, NOMAD, TOURER (VN1600) - WORKSHOP MANUAL - REPAIR MANUAL - WIRING DIAGRAMS - English Workshop Manual and Wiring Diagrams, to motorcycles Kawasaki Vulcan 1600 Classic Nomad Tourer VN1600 CONTENTS: - KAWASKI VULCAN 1600 CLASSIC (SERVICE) - KAWASKI VULCAN 1600 NOMAD, CLASSIC TOURER (SERVICE) - KAWASKI VULCAN 1600 NOMAD, CLASSIC TOURER (ASSEMBLY) INDEX: Foreword General Information - Before starting to perform an inspection service or carry out a - Battery Ground - Edges of Parts - Solvent - Cleaning vehicle before disassembly - Arrangement and Cleaning of Removed Parts - Storage of Removed Parts - Inspection - Replacement Parts - Assembly Order - Tightening Sequence - Tightening Torque - Force - Gasket, O-ring - Liquid Gasket, Locking Agent - Press - Ball Bearing and Needle Bearing - Oil Seal, Grease Seal - Circlips, Cotter Pins - Lubrication - Direction of Engine Rotation - Electrical Wires - VN1600-A1 (US, and Canada) Left Side View: - VN1600-A1 (US, and Canada) Right Side View: - VN1600-A1 (Europe) Left Side View: - VN1600-A1 (Europe) Right Side View: - Prefixes for Units: - Units of Temperature: Periodic Maintenance - The scheduled maintenance must be done in accordance with this c - The following tables list the tightening torque for the major fa - Steering Stem Nut Wrench : - Fuel System (DFI) - Fuel Hose and Connection Inspection - Throttle Control System Inspection - Idle Speed Inspection - Air Cleaner Element Cleaning - Evaporative Emission Control System Inspection (CAL) - Cooling System - Engine Top End - Clutch - Engine Lubrication System - Wheel/Tires - Final Drive - Brakes - Suspension - Steering - Electrical System - General Lubrication - Nut, Bolt, and Fastener Tightness Fuel System (DFI) - Terminal Numbers of ECU Connectors - Oil Pressure Gauge, 5 kgf/cm : - There are a number of important precautions that should be follo - Special Tool - - Torque - - Outline - Special Tool - - Special Tool - - DFI Diagnosis Flow Chart - Inquiries to Rider - NOTE - Self-diagnosis Procedures - Service Code Reading - Service Code Erasing - Throttle Sensor Removal/Adjustment - Input Voltage Inspection - Output Voltage Inspection - Resistance Inspection - Removal - Installation - Input Voltage Inspection - Output Voltage Inspection - Pv = 24 ~ 55 cm Hg - Pv = 55 ~ 86 cm Hg - Removal/Installation - Torque - - Output Voltage Inspection - Sensor Resistance Inspection - Removal/Installation - Torque - - Output Voltage Inspection - Water Temperature Sensor Resistance Inspection - Removal - Installation - Input Voltage Inspection - Output Voltage Inspection - Crankshaft Sensor ##1: for Front Cylinder (Service Code 21) - Crankshaft Sensor Removal/Installation - Crankshaft Sensor Inspection - Vehicle-down Sensor Removal - Installation - Vehicle-down Sensor Inspection - Fuel Injector ##1: Front Fuel Injector for Front Cylinder (Servic - Injector Removal - Injector Installation - Audible Inspection - Power Source Voltage Inspection - Output Voltage Inspection - Injector Signal Test - Injector Resistance Inspection - Injector Unit Test - Fuel Pump Removal - Fuel Pump Installation - Pressure Regulator Removal - Pump Screen, Fuel Filter Cleaning - Operation Inspection - Operating Voltage Inspection - Power Source Voltage Inspection - Operating Voltage Inspection - Ignition Coil ##1: Ignition Coil for Front Cylinder (Service Code - Removal/Installation - Input Voltage Inspection - Inspection Flow Chart - LED Light Inspection - ECU Identification - ECU Removal - ECU Installation - ECU Power Supply Inspection - DFI Fuse Removal - DFI Fuse Inspection - DFI Main Relay Removal - DFI Main Relay Inspection - DFI Power Source Circuit - Removal/Installation - Power Source Voltage Inspection - Output Voltage Inspection - Resistance Inspection - Fuel Pressure Inspection - Special Tools - - Fuel Flow Rate Inspection - Throttle Grip Free Play Inspection - Throttle Grip Free Play Adjustment - Choke Knob Operation - Choke Cable Free Play Inspection - Cable Removal/Installation - Cable Lubrication and Inspection - Idle Speed Check - Idle Speed Adjustment - Throttle Bore Cleaning - High Altitude Performance Adjustment - Throttle Body Assy Removal - Throttle Assy Installation - Throttle Assy Disassembly/Assembly - Element Removal - Element Cleaning - Left Air Cleaner Housing Removal/Installation - Right Air Cleaner Housing Removal - Right Air Cleaner Housing Installation - Lower Air Cleaner Duct Removal/Installation - Fuel Tank Removal - Fuel Tank Installation - Fuel Tank and Cap Inspection - Fuel Tank Cleaning - The Evaporative Emission Control System for California Model rou - Parts Removal/Installation - Canister Installation - Canister Inspection (Periodic Inspection) - Separator Inspection (Periodic Inspection) - Hose Inspection (Periodic Inspection) - Separator Operation Test Cooling System - Permanent type antifreeze is used as a coolant to protect the co - Bearing Driver Set : - Kawasaki Bond (Silicone Sealant) : 56019–120 - Coolant Deterioration Inspection - Coolant Level Inspection - Coolant Draining - Coolant Filling - Pressure Testing - Cooling System Flushing - Water Pump Removal - Water Pump Installation - Water Pump Inspection - Mechanical Seal Replacement - WARNING - Radiator Removal - Radiator Installation - Radiator Inspection - Radiator Cap Inspection - Radiator Filler Neck Inspection - Thermostat Removal - Thermostat Installation - Thermostat Inspection - Hose Installation - Torque - - Hose Inspection Engine Top End - Cam Height - Camshaft Journals and Runout - Valve Head Thickness - Valve Stem Bend - Valve Guide Reamer, 7 : 57001–162 - Air Suction Valve Removal - Air Suction Valve Installation - Air Suction Valve Check - Vacuum Switch Valve Removal - Vacuum Switch Valve Installation - Vacuum Switch Valve Operation Test - Vacuum Switch Valve Unit Test - Clean Air System Hose Inspection - Camshaft Chain Tensioner Removal - Camshaft Chain Tensioner Installation - Rocker Case Cover Removal - Rocker Case Cover Installation - Rocker Case Cover Assembly - Rocker Case Removal - Special Tool - - Rocker Case Installation - Rocker Arm Assembly - HLA Removal - HLA Air Bleeding - HLA Installation - Camshaft Removal - Special Tool - - Camshaft Installation - Camshaft Sprocket Installation - Camshaft/Rocker Case Wear - Front Camshaft Chain Removal - Rear Camshaft Chain Removal - KACR Inspection - Cylinder Compression Measurement - Special Tool - - Special Tools - - Torque - - Cylinder Head Removal - Cylinder Head Installation - Cylinder Head Warp - Valve Clearance Adjustment - Valve Removal - Valve Installation - Valve Guide Removal - Valve Guide Installation - Valve Guide Wear (Wobble Method) - Valve Seat Inspection - Valve Seat Repair - Cylinder Removal - Piston Removal - Cylinder, Piston Installation - Cylinder Wear - Piston Wear - Piston/Cylinder Clearance - Cylinder Boring and Honing - Piston Ring, Piston Ring Groove Wear - Piston Ring Groove Width - Piston Ring Thickness - Piston Ring End Gap - Exhaust Pipe Removal (For other than U.S.A. and Canadian Models) - Lower Muffler Removal (For other than U.S.A. and Canadian Models - Upper Muffler Removal (For other than U.S.A. and Canadian Models - Muffler, Exhaust Pipe Installation (For other than U.S.A. and Ca - Chamber Removal (For other than U.S.A. and Canadian Models) - Chamber Installation (For other than U.S.A. and Canadian Models) - Chamber Assembly (For other than U.S.A. and Canadian Models) - Chamber Identification (For other than U.S.A. and Canadian Model - Front Exhaust Pipe Removal (U.S.A. and Canadian Models) - Rear Exhaust Pipe Removal (U.S.A. and Canadian Models) - Muffler Removal (U.S.A. and Canadian Models) - Muffler, Exhaust Pipe Installation (U.S.A. and Canadian Models) Clutch - Inside Circlip Pliers : - Clutch Fluid Level Check - Clutch Fluid Change - Clutch Line Bleeding - Clutch Hose Removal/Installation - Clutch Hose and Connection Check - Clutch Lever Adjustment - Clutch Master Cylinder Removal - Clutch Master Cylinder Installation - Clutch Master Cylinder Disassembly/Assembly - Clutch Master Cylinder Inspection - Clutch Slave Cylinder Removal - Clutch Slave Cylinder Installation - Clutch Slave Cylinder Disassembly/Assembly - Clutch Cover Removal - Special Tools - - Clutch Removal - Clutch Installation - Inner Clutch Hub Disassembly - Spring Plate Gap Measurement - Spring Plate Gap Adjustment - Friction and Steel Plate Wear, and Damage Inspection - Friction or Steel Plate Warp - Clutch Spring Height Measurement - Clutch Housing Finger Inspection - Outer Clutch Hub Spline Inspection - Cam Damper Inspection Engine Lubrication System - Oil Pressure Gauge, 5 kgf/cm : - WARNING - Oil Level Inspection - Engine Oil Change - Oil Filter Replacement - Oil Pump Removal - Oil Pump Installation - Oil Hose Removal - Oil Hose Installation - Inside Oil Pipe Removal - Inside Oil Pipe Installation - Blowby Gas System Inspection - Breather Drain Cleaning - Oil Pressure Measurement - Special Tools - - Torque - - Relief Valve Inspection Engine Removal/Installation - Jack : 57001–1238 - Attachment Jack : 57001–1398 - Engine Removal - Special Tools - - Engine Installation Crankshaft/Transmission - Outside Circlip Pliers : - Crankcase Disassembly - Special Tool - - Special Tool - - Special Tool - - Crankcase Assembly - Starter Clutch Disassembly - Starter Clutch Assembly - Starter Clutch Inspection - Starter Torque Limiter Check - Connecting Rod Removal - Connecting Rod Installation - Crankshaft/Connecting Rod Cleaning - Connecting Rod Bend - Connecting Rod Twist - Connecting Rod Big End Side Clearance - Connecting Rod Big End Bearing Wear - Crankshaft Runout - Crankshaft Main Bearing/Journal Wear - Crankshaft Side Clearance - Primary Gear Removal - Special Tool - - Primary Gear Installation - Shift Pedal Removal - Shift Pedal Installation - External Shift Mechanism Removal - External Shift Mechanism Installation - External Shift Mechanism Inspection - Transmission Removal - Transmission Installation - Shift Drum Disassembly/Assembly - Transmission Disassembly - Transmission Assembly - Shift Fork Bending - Shift Fork/Gear Groove Wear - Shift Fork Guide Pin/Drum Groove Wear - Gear Dog and Gear Dog Hole Damage - Ball Bearing and Outer Race Replacement - Special Tool - - Ball and Needle Bearing Wear - Oil Seal Inspection Wheels/Tires - Inside Circlip Pliers : - Front Wheel Removal - Special Tools - - Front Wheel Installation - Rear Wheel Removal - Rear Wheel Installation - Wheel Coupling Removal - Wheel Coupling Installation - Wheel Inspection - Axle Inspection - Wheel Balance - Balance Inspection - Balance Adjustment - Balance Weight Removal - Balance Weight Installation - Air Pressure Inspection/Adjustment - Tire Inspection - Tire Removal - Tire Installation - Tire Repair - Hub Bearings Removal - Special Tool - - Special Tools - - Hub Bearings Installation - Hub Bearings Inspection - Hub Bearings Lubrication Final Drive - Bearing Puller : - Oil Level Inspection - Oil Change - Final Gear Case Removal - Final Gear Case Installation - Final Gear Case Disassembly - Final Gear Case - Backlash-Related Parts - Correct Tooth Contact Pattern: No adjustment is required. - Incorrect Tooth Contact Patterns (Example 1) - Incorrect Tooth Contact Patterns (Example 2) - Propeller Shaft Removal - Propeller Shaft Installation - Propeller Shaft Joint Lubrication - Propeller Shaft Inspection - Sliding Joint Inspection - Front Gear Case Removal - Front Gear Case Installation - Front Gear Case Disassembly - Front Gear Case Assembly - Driven Gear Disassembly - Driven Gear Assembly - Damper Cam Removal - Damper Cam Installation - Front Bevel Gear Adjustment - Front Bevel Gear Adjustment - Bearing Preloading Mechanism - Ball or Needle Bearing Replacement - Special Tools - - Special Tool - - Special Tool - - Ball Bearing Wear - Tapered Roller Bearing Inspection - Needle Bearing Inspection - Oil Seal Inspection Brakes - Inside Circlip Pliers : - Brake Lever Position Adjustment - Brake Pedal Position Adjustment - Brake Pedal Removal - Brake Pedal Installation - Front Caliper Removal - Rear Caliper Removal - Caliper Installation - Front Caliper Disassembly - Front Caliper Assembly - Rear Caliper Disassembly - Rear Caliper Assembly - Caliper Fluid Seal Damage - Caliper Dust Boot and Friction Boot Damage - Caliper Piston and Cylinder Damage - Caliper Holder Shaft Wear - Front Brake Pad Removal - Front Brake Pad Installation - Rear Brake Pad Removal - Rear Brake Pad Installation - Brake Pad Wear Inspection - Front Master Cylinder Removal - Front Master Cylinder Installation - Rear Master Cylinder Removal - Rear Master Cylinder Installation - Front Master Cylinder Disassembly - Rear Master Cylinder Disassembly - Master Cylinder Assembly - Master Cylinder Inspection - Brake Disc Removal - Brake Disc Installation - Brake Disc Wear - Brake Disc Warp - Brake Fluid Level Inspection - Brake Fluid Change - Brake Line Bleeding - Brake Hose Removal/Installation - Torque - Suspension - Fork Cylinder Holder Handle : - Fork Oil Change - Special Tool - - Torque - - Front Fork Removal - Front Fork Installation - Disassembly - Assembly - Inner Tube, Outer Tube Inspection - Dust Seal Inspection - Spring Tension - Rebound Damping Adjustment - Spring Preload Adjustment - Rear Shock Absorber Removal - Rear Shock Absorber Installation - Rear Shock Absorber Inspection - Swingarm Removal - Special Tools - - Swingarm Installation - Swingarm Bearing Removal - Swingarm Bearing Installation - Swingarm Bearing, Sleeve Inspection - Grease Seal and Needle Bearing Lubrication Steering - Head Pipe Outer Race Press Shaft : - Handlebar Removal - Handlebar Installation - Steering Check - Steering Adjustment - Steering Stem Removal - Special Tools - - Steering Stem Installation - Steering Stem Warp - Stem Bearing Removal - Special Tool - - Stem Bearing Installation - Stem Bearing Lubrication - Stem Cap Deterioration, Damage Frame - Jack : - Rear Seat Removal - Rear Seat Installation - Front Seat Removal - Front Seat Installation - Left Side Cover Removal - Left Side Cover Installation - Right Side Cover Removal/Installation - Front Fender Removal - Rear Fender Removal - Battery Case Removal - Tool Box Removal - Footboard Removal - Footboard Disassembly - Sidestand Installation - Downtube Removal - Special Tools - - Downtube Installation - Frame Inspection Electrical System - Spark Plug Wrench, Hex 18 : - Left Handlebar Switches [A] - There are a number of important precautions that should be follo - Wiring Inspection - Special Tool - - Battery Removal - Battery Installation - Electrolyte Filling - Initial Charge - Precautions - Interchange - Alternator Outer Cover Removal - Alternator Outer Cover Installation - Alternator Cover Removal/Installation - Alternator Cover Assembly - Alternator Inner Cover Removal - Alternator Inner Cover Installation - Alternator Rotor Removal - Alternator Rotor Installation - Alternator Outside Stator Removal - Alternator Outside Stator Installation - Alternator Inside Stator Removal - Alternator Inside Stator Installation - Charging Voltage Inspection - Alternator Inspection - Regulator/Rectifier Removal - Regulator/Rectifier Installation - Rectifier Inspection - Regulator Inspection - Charging System Circuit - Ignition System Circuit - Starter Motor Removal - Starter Motor Installation - Starter Motor Disassembly - Starter Motor Assembly - Brush Inspection - Commutator Cleaning and Inspection - Armature Inspection - Brush Assy Inspection - Brush Plate and Terminal Bolt Inspection - Starter Relay Inspection - Electric Starter Circuit - This model adopts the daylight system and has a headlight relay - Headlight Beam Horizontal Adjustment - Headlight Beam Vertical Adjustment - Headlight Bulb Replacement - Headlight Body Removal - City Light Bulb Replacement (other than US, CA and AU) - Tail/Brake Light Bulb Replacement - Headlight/Tail Light Circuit - Automobiles use a turn signal canceling system actuated by steer - Wiring Inspection - Distance Sensor Inspection - Turn Signal Switch Inspection - Turn Signal Switch Connections - Turn Signal Control Relay Inspection - Turn Signal Light Bulb Replacement - Turn Signal Cancelling System Circuit - WARNING - Fan System Circuit Inspection - Fan Motor Inspection - Radiator Fan Circuit - Motorcycle operation with low engine oil level, even if it is hi - Oil Pressure Warning System Circuit - Oil Pressure Light Delay Unit Removal - Oil Pressure Light Delay Unit Inspection - Meter Unit Removal - Meter Unit Installation - Meter Unit Disassembly - Meter Unit Assembly - Meter Unit Inspection - LED Light Inspection - Indicator Light Inspection - Meter Unit Circuit - Water Temperature Warning System Check - Fuel Level Sensor Inspection - Special Tool - - Torque - - Fuel Reserve Switch Inspection - Speed Sensor Removal - Speed Sensor Installation - Speed Sensor Inspection - Front Brake Light Switch Inspection - Rear Brake Light Switch Check/Adjustment - Radiator Fan Switch Removal - Radiator Fan Switch Installation - Radiator Fan Switch Inspection - Water Temperature Switch Removal - Water Temperature Switch Installation - Water Temperature Switch Inspection - Switch Inspection - Rear Brake Light Switch Connections - Side Stand Switch Connections - Neutral Switch Connections - Oil Pressure Switch Connections* - The junction box [A] has fuses [B], relays, and diodes. The rela - Junction Box Fuse Circuit Inspection - Starter Circuit/Headlight Relay Inspection - Diode Circuit Inspection - Junction Box Internal Circuit - Main Fuse Removal - Junction Box Fuse Removal - Fuse Installation - Fuse Inspection Appendix - NOTE - Engine Doesn't Start, Starting Difficulty: - Poor Running at Low Speed: - Poor Running or No Power at High Speed: - Overheating: - Over Cooling: - Clutch Operation Faulty: - Gear Shifting Faulty: - Abnormal Engine Noise: - Abnormal Drive Train Noise: - Abnormal Frame Noise: - Oil Pressure Warning Light Goes On: - Exhaust Smokes Excessively: - Handling and/or Stability Unsatisfactory: - Brake Doesn't Hold: - Battery Trouble:
Kawasaki Vulcan 1600 Classic Nomad Tourer VN1600 - Repair, Workshop Manual - Wiring Diagrams
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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