Kawasaki Vulcan 1600 Classic, Mean Streak & Nomad 2003 - 2008

Clymer Owners Service & Repair

2003, 2004, 2005, 2006, 2007, 2008

by Clyme Staff

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Kawasaki Vulcan 1600 Classic, Mean Streak & Nomad 2003 - 2008 - Front Cover

Front Cover

Front Cover

description

Kawasaki Vulcan 1600 Classic, Mean Streak & Nomad 2003 - 2008 Clymer Owners Service & Repair covers the following models:
● Kawasaki Vulcan VN1600 Classic A, E, 2003-2008
● Kawasaki Vulcan VN1600 Mean Streak B, F, 2004-2008
● Kawasaki Vulcan VN1600 Nomad D, G, 2005-2008

Contents:
QUICK REFERENCE DATA

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

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 / Tyres 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 TYRES
Motorcycle lift / Front wheel / Rear wheel / Front and rear hubs / Rear wheel coupling / Wheel service / Tyre 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

COLOUR WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

General information on Repair Manuals

Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.

product details

  • Publisher: Clymer Publications
  • ISBN: 1599695146 (1-599-69514-6)
  • ISBN-13: 9781599695143 (978-1-599-69514-3)
  • Format: Softcover, 462 pages
  • Date Published: 09-2011

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