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1996-2008 Kawasaki VN1500 Vulcan Clymer Motorcycle Repair Manual

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Description

This Clymer Kawasaki VN1500 Vulcan 1996-2008 Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for the following Kawasaki VN1500 motorcycles:

VN1500 Vulcan Classic D1-D2 (1996-1997)
VN1500 Vulcan Classic E1-E7 (1998-2004)
VN1500 Vulcan Classic N1-N8 (2000-2008)
VN1500 Vulcan Classic T6 (2006)
VN1500 Vulcan Drifter J1-J2 (1999-2000)
VN1500 Vulcan Drifter R1-R5 (2001-2005)
VN1500 Vulcan Nomad G1, G1A, G2A, G3 (1998-2001)
VN1500 Vulcan Nomad L1-L5 (2000-2004)

1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

This Clymer Kawasaki VN1500 Vulcan 1996-2008 Repair Manual includes the following information:

QUICK REFERENCE DATA

CHAPTER ONE/GENERAL INFORMATION
Manual organization/Warnings,cautions and notes/Safety/Serial numbers/Fasteners/Shop supplies/Tools/Measuring tools/Electrical system fundamentals/Service methods/Storage/Specifications

CHAPTER TWO/TROUBLESHOOTING
Starting the engine/Engine does not start/Engine performance/Electronic diagnostic system/Engine noises/Engine lubrication/Clutch/Gearshift linkage/Transmission/Fuel system/Electrical testing/Lighting system/Charging system/Ignition system/Starting system/Front suspension and steering/Brake system/Specifications

CHAPTER THREE/LUBRICATION, MAINTENANCE AND TUNE-UP
Tune-up/Air filter/Engine oil and filter/Idle speed adjustment/Spark plugs/Battery/Compression test/Ignition timing inspection/Brake system/Clutch system/Cooling system/Fuel hose inspection/Emission control systems/Throttle cable operation and adjustment/Control cable lubrication/Gearshift pedals/Tires and wheels/Lights and horn inspection/Sidestand switch and ignition cut-off system/Steering head bearing inspection/Front suspension inspection/Rear suspension inspection/Swing arm bearing inspection/Final drive unit/Speedometer cable lubrication/Fasteners/Specifications

CHAPTER FOUR/ENGINE TOP END
Shop cleanliness/Engine/Rocker case cover/Rocker case/Camshaft and cam chain tensioner/External oil hoses/Cylinder head/Valves/Cylinder/Piston and piston rings/Specifications

CHAPTER FIVE/ENGINE LOWER END
Right crankcase cover/Left crankcase outer cover/Front bevel gearcase/Bevel gears/Bevel gears/Driven gear/Primary drive gear and water pump drive mechanism/Starter gears/Oil pump/Balancer weights/Balancer drive gear/Balancer shaft/Crankcase/Crankshaft and connecting rods/Break-in/Specifications

CHAPTER SIX/CLUTCH AND EXTERNAL SHIFT MECHANISM
Gearshift pedals/Gearshift pedal shaft/External gearshift mechanism/Clutch/Clutch inner hub/Clutch master cylinder/ Clutch hose assembly/Slave cylinder/Clutch hydraulic system/Specifications

CHAPTER SEVEN/TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission/Transmission inspection/Internal gearshift mechanism/Specifications

CHAPTER EIGHT/CARBURETOR, FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS
Carburetor/Throttle position sensor (TPS)/Throttle cable replacement/Choke cable replacement/Air filter housing/Fuel tank/Fuel valve/Fuel level sensor/Fuel pump/Fuel filter/Crankcase breather inspection/Clean air system/Evaporative emission control system/Exhaust system/Specifications

CHAPTER NINE/FUEL INJECTION, EMISSION CONTROL AND EXHAUST SYSTEM
Digital fuel injection (DFI)/Fuel delivery system tests/Fuel pump/Fuel injection main relay/Fuel pressure regulator/Induction system/Idle speed control valves/Throttle body/Intake manifold/Fuel injectors/Throttle position sensor (TPS)/Atmospheric pressure (AP) sensor/Vacuum sensor/Engine coolant temperature (ECT) sensor/Intake air temperature (IAT) sensor/Vehicle-down sensor/Ignition pickup coils/Fuel tank/Fuel return check valve/Fuel level system/Clean air system/Evaporative emission control system/Throttle cable replacement/Choke cable replacement/Exhaust system/Specifications

CHAPTER TEN/ELECTRICAL SSYSTEM
Electrical component replacement/Electrical connectors/Negative battery cable/Battery/Charging system/Regulator-rectifier/Alternator rotor and stator/Ignition system/Starting system/Starter/Starter relay/Starter circuit relay/Lighting system/Switches/Oil pressure warning system/Relays/Meter unit(L2-L4, N, R and T models), Turn signal canceling system/Speed sensor (L2-L4, N, R and T models)/Fuel level system/Cooling system/Fuel pump (D, E and G models)/Fuses and junction box/Wiring diagrams/Specifications

CHAPTER ELEVEN/COOLING SYSTEM
Cooling system safety/Radiator and fan/Cooling fan switch/Coolant temperature sending unit/Thermostat/Water pump/Specifications

CHAPTER TWELVE/WHEELS AND TIRES
Front wheel/Rear wheel/Rear wheel coupling/Wheel and axle inspection/Front and rear hubs/Laced wheels/Tires/Wheel balance/Specifications

CHAPTER THIRTEEN/FRONT SUSPENSION AND STEERING
Handlebar/Front fork/Steering head and stem/Steering head bearings/Steering bearing adjustment/Specifications

CHAPTER FOURTEEN/REAR SUSPENSION AND FINAL DRIVE
Shock absorber/Final drive unit/Swing arm and drive shaft/Specifications

CHAPTER FIFTEEN/BRAKES
Brake service/Brake pad replacement/Front brake caliper/Rear brake caliper/Caliper repair/Front master cylinder/Rear master cylinder and brake pedal/Brake bleeding/Brake disc/Specifications

CHAPTER SIXTEEN/BODY AND FRAME
Front seat/Rear seat/Side covers/Front footrests/Rear footpegs/Rear footrests/Sidestand/Front fender/Rear fender/Saddlebags/Windshield and brackets/Wind deflectors/Front frame guard/Steering head covers/Specifications

INDEX

WIRING DIAGRAMS

1996 1997 1998 1999
2000 2001 2002 2003 2004 2005 2006 2007 2008

Additional information

Weight 2.29375 lbs
Dimensions 9 × 7 × 0.5 in
ISBN

9781599691701