Description
This 2003-2008 Kawasaki Vulcan VN1600 Motorcycle Repair Manual By Clymer provides repair, service, and maintenance information for 2003-2008 Kawasaki Vulcan VN1600 motorcycles.
This Kawasaki Vulcan VN1600 Motorcycle Repair Manual covers the following Kawasaki Vulcan VN1600 Motorcycles:
2008 Kawasaki VN1600E8F Vulcan Classic
2008 Kawasaki VN1600D8F Vulcan Nomad
2008 Kawasaki VN1600B8F Vulcan Mean Streak
2008 Kawasaki VN1600A8F Vulcan Classic
2007 Kawasaki VN1600D7FL Vulcan Nomad
2007 Kawasaki VN1600D7FA Vulcan Nomad
2007 Kawasaki VN1600D7F Vulcan Nomad
2007 Kawasaki VN1600B7FL Vulcan Mean Streak
2007 Kawasaki VN1600B7FA Vulcan Mean Streak
2007 Kawasaki VN1600B7F Vulcan Mean Streak
2007 Kawasaki VN1600A7F Vulcan Classic
2006 Kawasaki VN1600F6F Mean Streak
2006 Kawasaki VN1600D Vulcan Nomad
2006 Kawasaki VN1600B6F Mean Streak
2006 Kawasaki VN1600A6F Vulcan Classic
2006 Kawasaki VN1600 Vulcan Classic
2005 Kawasaki VN1600D1 Vulcan Nomad
2005 Kawasaki VN1600B2 Mean Streak
2005 Kawasaki VN1600A3 Vulcan Classic
2004 Kawasaki VN1600B1 Mean Streak
2004 Kawasaki VN1600A2 Vulcan Classic
2003 Kawasaki VN1600A1 Vulcan Classic
Table of Contents:
2003-2008 Kawasaki Vulcan VN1600 Motorcycle Repair Manual By Clymer Quick Reference Data:
Kawasaki Vulcan 1600 Motorcycle, General Information
Manual organization, Warnings, cautions and notes, Safety, Serial numbers and information labels, Fasteners, Shop supplies, Tools, Measuring tools, Electrical system fundamentals, Service methods, Storage, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Troubleshooting
Starting the engine, Engine does not start, Poor engine performance, Electronic diagnostic system, Fuel system, Engine, Engine lubrication, Cylinder leakdown test, Clutch, Gearshift linkage, Transmission, Electrical testing, Charging system, Ignition system, Starting system, Final drive, Front suspension and steering, Brake system, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Periodic Lubrication, Maintenance and Tune-up
Maintenance schedules, Tune-up, Cylinder identification and firing order, Air filter, Engine compression test, Spark plugs, Ignition timing, Idle speed adjustment, Fuel hose inspection, Fuel pump screen and fuel filter, Throttle cable, Choke cable, Control cable lubrication, Brake and clutch lever lubrication, Clutch, Engine oil and filter, Cooling system, Evaporative emission control systems, Battery, Final drive oil, Drive shaft lubrication, Tires and wheels, Steering bearings, Front suspension check, Rear suspension check, Brakes, Headlight adjustment, Sidestand and ignition cut-off switch test, Engine stop switch check, Front fork oil change, Swing arm bearing lubrication, General lubrication, Fastener inspection, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Engine Top End
Rocker case cover, Rocker case, Cam chain tensioner, Camshaft, External oil hoses, Cylinder head, Valves and valve components, Cam chain and chain guide, Cylinder, Piston and piston rings, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Engine Lower End
Servicing engine in frame, Engine removal/installation, Shift pedal and shift linkage, External shift mechanism, Front bevel gearcase, Drive gear, Driven gear, Front bevel gear adjustments, Starter gears, Primary drive gear and water pump drive mechanism, Balancer gears, Crankcase, Crankcase bearings, Crankshaft, Connecting rods, Balancer shaft, Oil pump and oil pressure relief valve, Break-in, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Clutch
Kawasaki Vulcan VN1600 Motorcycle, Transmission And Shift Mechanism
Transmission, Internal gearshift mechanism, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Fuel System
Digital fuel injection (DFI), Fuel tank, Fuel return check valve (B and F models), Fuel pump operation test, Fuel pressure test, Fuel pump discharge test, Fuel pump, Fuel injection main relay, Fuel pressure regulator, Electronic control unit (ECU), Induction system, Idle speed control (ISC) valves, Fuel injectors, Throttle body and intake manifold, Throttle sensor, Intake air pressure (IAP) sensor, Intake air temperature (IAT) sensor, Water temperature sensor, Atmospheric pressure (AP) sensor, Crankshaft sensors, Vehicle-down sensor, FI indicator, Throttle cable, Choke cable, Clean air system, Evaporative emission control system (California only), Specifications
Kawasaki Vulcan VN1600 Motorcycle, Electrical System
Electrical component replacement, Electrical connectors, Battery, Charging system, Regulator/rectifier, Left crankcase outer cover, alternator covers, stator coils, crankshaft sensors and rotor, Ignition system, Peak voltage testing, Ignition coils, Crankshaft sensors, Electronic control unit (ECU), Ignition timing, Starting system, Starter, Starter relay, Starter circuit relay, Lighting system, Front turn signal housing, Headlight relay, Meter unit, Indicator panel (B and F models),, Turn signal cancelling system, Speed sensor, Fuel level system, Radiator fan, Radiator fan switch, Water temperature switch, Oil pressure light delay unit, Oil pressure switch, Sidestand interlock system test, Switch continuity test, Ignition switch, Front brake light switch, Rear brake light switch, Starter lockout switch, Neutral switch, Sidestand switch, Handlebar switch, Relays, Fuel level indicator light and water temperature warning LED diodes (B and F models), Fuses and junction box, Color wiring diagrams, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Cooling System
Cooling system inspection, Radiator, Radiator fan, Coolant reserve tank, Thermostat, Water pump, Specifications
Kawasaki Vulcan VN1600 Motorcycle. Wheels and Tires
Motorcycle lift, Front wheel, Rear wheel, Front and rear hubs, Rear wheel coupling, Wheel service, Tire service, Wheel balance, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Front Suspension
Handlebar, Handlebar grips, Steering assembly, Steering adjustment, Steering head bearing race, Steering stem bearing, Front fork, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Rear Suspension and Final Drive
Shock absorber, Final drive unit, Swing arm and drive shaft, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Brakes
Brake service notes, Brake bleeding, Brake fluid draining and flushing, Brake pads, Brake caliper removal/installation, Brake caliper overhaul, Front master cylinder, Rear master cylinder, Rear brake pedal and footrest bracket, Brake hoses, Brake disc, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Body and Exhaust Systems
Rear seat (A, D, E and G models), Front seat, Side covers, Front footrests, Sidestand, Front fender, Rear fender, Saddlebags (D and G models), Windshield, sub-windshield and wind deflectors (D and G models), Front frame guards (D and G models), Rear frame guards (D and G models), Backrest and hand grips (D and G models), Downtube, Exhaust system, Specifications
Kawasaki Vulcan VN1600 Motorcycle, Index
Kawasaki Vulcan VN1600 Motorcycle, Wiring Diagrams
