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Kawasaki Vulcan 1600 Series Manual 2003-2008
Kawasaki Vulcan Manual
Kawasaki Vulcan Manual (1600 Series)


 
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Product Code: M245

Description
 

Kawasaki Vulcan 1600 Manual

This Clymer motorcycle manual covers the Kawasaki Vulcan 1600 Series for these model years:
 
2003-2008 Kawasaki Vulcan Classic
2004-2008
Kawasaki Vulcan Mean Streak
2005-2008
Kawasaki Nomad

The Kawasaki Vulcan manual by Clymer is the best reference book for repair and service information for your Vulcan 1600 motorcycle. Every Clymer motorcycle service manual is written for the do-it-yourselfer as well as the experienced mechanic, Clymer motorcycle repair manuals are the cheapest way to keep your motorcycle running properly. Every Clymer motorcycle service manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the motorcycle covered. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail, accuracy and clarity to guide the reader through each service, troubleshooting and repair procedure.
 
The Kawasaki Vulcan manual includes the following chapter information:

GENERAL INFORMATION

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

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

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

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

CLUTCH
Clutch bleeding / Clutch fluid draining and flushing / Clutch master cylinder / Clutch slave cylinder / Clutch cover / Clutch / Inner hub / Specifications

TRANSMISSION and INTERNAL SHIFT MECHANISM
Transmission / Internal gearshift mechanism / Specifications

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 / Specifications

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

COOLING SYSTEM
Cooling system inspection / Radiator / Radiator fan / Coolant reserve tank / Thermostat / Water pump / Specifications

WHEEL and TIRES
Motorcycle lift / Front wheel / Rear wheel / Front and rear hubs / Rear wheel coupling / Wheel service / Tire service / Wheel balance / Specifications

FRONT SUSPENSION and STEERING
Handlebar / Handlebar grips / Steering assembly / Steering adjustment / Steering head bearing race / Steering stem bearing / Front fork / Specifications

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

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

BODY and EXHAUST SYSTEM
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

INDEX

COLOR WIRING DIAGRAMS

Kawasaki Vulcan 1600 Models covered:
Vulcan Classic A1 A2 A3 2003 2004 2005
Vulcan Classic A6F and E6F 2006
Vulcan Classic A7F and A7FA 2007
Vulcan Classic A8F and A8FA 2008
Vulcan Mean Streak B1 - B2 2004 2005
Vulcan Mean Streak B6F and F6F 2006
Vulcan Mean Streak B7F and B7FA 2007
Vulcan Mean Streak B8F and B8FA 2008
Vulcan Nomad D1 2005
Vulcan Nomad D6F and G6F 2006
Vulcan Nomad D7F and D7FA 2007
Vulcan Nomad D8F and D8FA 2008



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