by Ed Scott
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Quote order code CM471-3
Kawasaki Vulcan 1500 Series 1996 - 2008 Clymer Owners Service & Repair Manual covers the following models:
● Vulcan 1500 Classic D1-D2 (1996-1997)
● Vulcan 1500 Classic E1-E7 (1998-2004)
● Vulcan 1500 Classic N1-N8 (2000-2008)
● Vulcan 1500 Classic T6 (2006)
● Vulcan 1500 Drifter J1-J2 (1999-2000)
● Vulcan 1500 Drifter R1-R5 (2001-2005)
● Vulcan 1500 Nomad G1, G1A, G2A, G3 (1998-2001)
● Vulcan Nomad L1-L5 (2000-2004)
Note: this manual does not cover Classic Fi, Nomad or Drifter models. See Clymer CM357-2 for 1987-1999 Vulcan 1550A, B and C models.
● QUICK REFERENCE DATA
● GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Washing the bike / Special tips / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Gasket remover / Threadlocking compound / Expendable supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Special tools / Fabricating tools / Mechanicfs tips / Ball bearing replacement / Seals / Riding safety / Storage / Specifications
Operating requirements / Troubleshooting instruments / Starting the engine / Emergency troubleshooting / Engine starting troubleshooting / Engine performance / Engine noises / Engine lubrication / Clutch / Gearshift linkage / Transmission / Electrical troubleshooting / Test equipment / Basic test procedures / Electrical problems / Charging system troubleshooting / Ignition system troubleshooting / Starter system troubleshooting / Carburetor troubleshooting / Excessive vibration / Front suspension and steering / Brake problems / Specifications
● 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 / Tyres 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 lubrication / Final drive unit / Speedometer cable lubrication / Fasteners / Specifications
● 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
● ENGINE LOWER END END
Right crankcase cover / Left crankcase outer cover / Front bevel gearcase / 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
● CLUTCH AND EXTERNAL SHIFT MECHANISM
Gearshift pedals / Gearshift pedal shaft / External gearshift mechanism / Clutch inner hub / Master cylinder / Clutch hose assembly / Slave cylinder / Specifications
● TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission / Transmission inspection / Internal gearshift mechanism / Specifications
● CARBURETOR, FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS
Throttle position sensor TPS / Fuel tank / Fuel valve / Fuel level sensor / Fuel pump / Fuel filter / Crankcase breather inspection / Clean air system / Evaporative emission control system / Specifications
● 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 / Exhaust system / Specifications
● ELECTRICAL SYSTEM
Charging system / Regulator-rectifier / Alternator rotor and stator / Ignition system / Starting system / Starter / Lighting / Switches / Oil pressure warning system / Relays / Meter unit / Turn signal canceling system / Speed sensor / Fuel level system / Fuel pump / Fuses and junction box / Specifications
● COOLING SYSTEM
Radiator and fan / Cooling fan switch / Coolant temperature sending unit / Thermostat / Water pump / Specifications
● WHEELS AND TYRES
Front wheel / Rear wheel / Rear wheel coupling / Wheel and axle inspection / Front and rear hubs / Laced wheels / Cast wheels / Wheel balance / Tyres / Specifications
● FRONT SUSPENSION AND STEERING
Handlebar / Front fork / Steering head and stem / Steering head bearings / Steering bearing adjustment / Specifications
● REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Final drive unit / Swing arm and drive shaft / Specifications
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
● 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
● 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.
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.
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