Instruction/ maintenance manual of the product 1600 Kawasaki
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VULCAN 1600 NOMAD VN1600 CLASSIC TOURER Motorcycle Assembly & Preparation Manual.
Foreword In order to ship Kawasaki vehicles as effi- ciently as possible, they are partially disassem- bled before crating. Since some of the most commonly removed parts have a direct bear- ing on a vehicle’ s reliability and safety , consci- entious pre-sale assembly and preparation be- comes extremely important.
T able of Contents Un crating ...................................................................................... 3 Opening Crate ............................................................................. 3 Parts Check ..........................
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UNCRA TI NG 3 Uncrating Opening Crate • Clear a space about 6 m (20 ft.) square to give yo urself plenty of space to work. • Place the crate upright on its base. • Remove the cardboard cover . • Remov e the handlebar , front wheel, and the parts box.
4 UNCRA T ING Parts Check • Open the parts box, and check the parts against the illustrations. There may be minor differences between these illustrations and the actual vehicle parts. In the following charts under Remarks, D = diameter in millimeters, L = length in millimeters, and T = Thickness in millimeters.
UNCRA TI NG 5 No. Part Name Qty Remarks 1 Handlebar with Grip 1 Handlebar Clamp 2 Clamp Bolt, Socket 4 D = 10, L = 23 Plastic Plug, Clamp Bolt 4 Large Throttle Grip 1 Clamp, Master Cylinder 2 Clamp Bolt, Master Cylinder , Socket 4 D=6 ,L=2 0 Plastic Plug, Clamp Bolt 4 Small Plastic Clamp, Wiring and Hose 4 L = 88.
6 UNCRA T ING * : European Models Only.
UNCRA TI NG 7 No. Part Name Qty Remarks 8 Horn with Bracket 1 Flanged Bolt, Horn 1 9 Licen se Plate Bracket 1 Bolt, Bracket, License Plate 2 D=6 ,L=1 2 Bracket, Reflector 1 (US)(CN)(AUS) only Refl ect.
8 ASSEMB LY Assembly Handlebar NOTE ż Position the handlebar clamp on the handle- bar with the slanted side facing rearward. • Set th e handlebar to match its punched mark to the rear portion of the lo wer clamp mating face and install the upper clamps and bolts (D =1 0 ,L = 23).
ASSEMBL Y9 A. Right Switch Housing B. S crews (L = 25) C. Harness D. Throttle Cable (Accelerator) E. Throttle Cable (Decelerator) F . Holder Screw Front Brake Master Cylinder • Connect the right switch housing le ad con- nectors to the front brake light switch termi- nals on the front brake master cylinder .
10 ASSEM BL Y Clutch Master Cylinder • Apply silicone grease or PBC grease to the master cylinder clamp bolts. • Install the clutch master cylinder with its clamp and the two socket bolts (D = 6, L = 20).
ASSEMBL Y1 1 A. Left Switch Lead B. Clutch Hose C. Fasten the left switch lead and the clutch hose with two plastic clamps. D. Fasten the right switch lead with the plastic clamp. E. Fasten the right switch lead and the brake hose with the plastic clamp.
12 ASSEM BL Y Front Fender Installation • Lift the motorcycle off the crate b ase and sup- port the motorcycle with a suitable stand or jack. • Loosen the axle clamp bolts on the right fork leg and remove the front axle. • Loosen the two flanged bolts (D = 10, L = 47) to remove each front brake caliper .
ASSEMBL Y1 3 A. Front Tire B. Arrow C. Rotation • Fit the axle collars on both sides of the front wheel hub. The collars are identical. • Put the front wheel assembly between the fork legs. • Insert the front axle from the right side of the wheel and push it completely through.
14 ASSEM BL Y • Check the front brake. A. Front Brake Caliper (Left) B. Bo lts (D = 10, L = 47) WA R N I N G Do not attempt to ride the motorcyc le un- til a full brake lever is obtained by pump- ing the brake lever until the pads are against the disc.
ASSEMBL Y1 5 Front Footboard (Left) NOTE ż Install the left footboard after the “Clutch Fluid” sectio n in the Preparation chapter . • Install the left footboard assembly on the frame with one bolt (D = 10, L = 30) at the rear and tighten it. A.
16 ASSEM BL Y Helmet Locks • Unlock the helmet lock with the key and fit the small projection of the lock into the hole in the bracket of each rear guard and fasten it with the screw (D = 5, L = 12) having a non-permanent locking agent. • Lock the helmet lock.
ASSEMBL Y1 7 Label Installation (for US and CN Mod- els only) • Wipe off any oil or g rease from the application area. • Peel the warning label off the backing sheet and stick it on the rear left guard. A. Rear Guard (Left) B. Label For US Models (56070-1285) C.
18 ASSEM BL Y A. Horn B. B olt (D = 8, L = 12) C. Bracket Choke Knob • Loosen the locknut and fasten the choke knob to the bracket with locknut. A. Choke Knob B. Locknut C. Bracket Rear View Mirr ors (Left and Right) Conventional T ype (Single Nut) • Loosen the locknut completely .
ASSEMBL Y1 9 A. Lower Hexagonal Area for Tightening B. Upper Hexagonal Area (Adapter) C. Stay D. Non-permanent Locking Agent applied. • T urn the stay to assure visibility to the rear with the operator sitting on the motorcycle. • Adjust the rear view mirror by slightly moving only the mirror portion of the assembly .
20 ASSEM BL Y A. Windshield Assembly B. Socket Bolts (D = 8, L = 10) T rim Installation [EUR Models Only] • Fit the windshield trim onto the edge of the windshield starting from each lower edge. • Fix the trim ends with the clamps (2). A. T rim B.
ASSEMBL Y2 1 A. Bolts B. Sub-windshield License Plate Bracket License Plate Bracket Installation • Install the license plate bracket onto the rear fender with the bolts (D = 6, L = 12)(2).
22 ASSEM BL Y A. Reflector B. License Plate Holder C. C ap Nut (D = 5) • Install the license plate holder on the license plate bracket with the bolts (D = 6, L = 14)(3) and plated cap nuts (3) and tighten them. The remaining fasteners are used for the license plate.
ASSEMBL Y2 3 A. Lock B. Left Saddlebag C. L ocked-position Mark D. Projections E. Notches NOTE ż Push the lid lock all the way into the hole in the lid so that the projection ends are inserted into it. A. Lock • T urn the key clockwise and counterclockwise, to check the saddlebag lid lock operation.
24 PREP A RA TION • Measure the clearances between both the front and rear upper dampers and the up- per mounting bracket with the saddlebag lightly pushed by hand against the mounting bracket. • If the clearance is 1.0 mm (0.04 in.) or more at the front and/or rear , adjust it.
PREP ARA TION 25 B a t t e r yM o d e lN a m ef o r VN1600–D1: FTZ16–BS A. Model Name of the Electrolyte B. Model Name of the Battery CAUTION Sealed battery electrolyte has a higher concentration of sulfuric acid. Each container contains the proper amount of electrolyte for its specific battery .
26 PREP A RA TION A. Wiring Clamp B. 1 P Connector (Negative Lead) C. 2 P Connector D. 3 P Connector E. B attery Holder Nuts F . Battery Holder G. Battery H . 6 P Connector (Rear Harness) I. 4 P Connector (Diagnosis) J. Plastic Clamp K . 15 A Fuse Holder L.
PREP ARA TION 27 • Place the electrolyte container upside down with the six sealed cells into the filler ports of the battery . Hold the container level, push down to break the seals of all six cells. Y ou will see air bubbles rising into each cell as the ports fill.
28 PREP A RA TION CAUTION Once the strip of caps [A] is installed onto the battery , never remove the caps, nor add water or electrolyte to the bat- tery . NOTE ż T o ensure maximum battery life and customer satisfaction, it is recommended the battery be loa d tested at three times its amp-hour rating for 15 seconds.
PREP ARA TION 29 Viewed from Right A. Positive T erminal (+) B. Battery C. Positive Cable (+) D. ECU Relay E. Negative Cable (–) Viewed from T op A. Negative Cable (–) B. Run the Positive Cable (+) through the Guide in the Battery Case. C. Positive Cable (+) D.
30 PREP A RA TION A. Bolt (D = 6, L = 14) B. P assenger ’ s Seat Front Brake Fluid Front Brake Fluid Level Inspection • With the front brake fluid reservoir held hori- zontal, check that the fluid level is above the lower level line. A. Front Brake Fluid Reservoir B.
PREP ARA TION 31 • Attach a clear plastic hose to the bleed valve on each front brake caliper and run the other end of the hose into a container . • With the reservoir cap off, slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir .
32 PREP A RA TION • Operate the brake lever several times. • If it feels spongy , th ere might be air in the brake line. • If necessary , bleed the air in the rear brake line.
PREP ARA TION 33 A. Clutch Fluid Reservoir B. Upper Level Line • Operate the clutch lever several times. • If it feels spongy , there might be air in the line. • If necessary , bleed the air in the lines. • Also check for fluid leakage around the fit- tings.
34 PREP A RA TION Rear Shock Absorber Air Pre ssure Adjustment STD Air pressure: Atmospheric Rebound Damping Force Adjustment • Check the position of the rebound damping force adjuster at the upper end of each rear shock absorber . It has four positions.
PREP ARA TION 35 A. F ( Full) Mark B. L (Low) Mark C. Right Side Cover Coolant Filling • If the amount of coolant is insufficient, remove the right side cover , pull open the cap from the reserve tank and add coolant through the filler opening to the F (Full) mark.
36 PREP A RA TION A. Oil Filler Cap B. O il Level Sight Gauge C. H (High) Level Line D. L (Low) Level Line • If the oil level is too high, remove the excess oil through the oil filler opening, using a sy- ringe or some other suitable device. • If the oil level is too low , add oil to reach the correct level.
PREP ARA TION 37 • When replacing the filler cap, be sure the O -ring is in place, and install the cap. Final G ear Case Oil Ty p e : API “GL-5” Hypoid gear oil Viscosity: SAE 90 [above 5°C (41°F)] SAE 80 [below 5°C (41°F)] Capacity: 0.2 L (0.
38 PREP A RA TION Headlight Aim The headlight beam is adjustable both hori- zontally and vertically . Headlight aim must be correctly adjusted for safe riding as well as on- coming drivers. In most areas it is illegal to ride with an improperly adjusted headlight.
PREP ARA TION 39 A. Rear Brake Light Switch B. Adjusting Nut C. Lights sooner . D. Lights later . CAUTION T o avoid damaging the electrical con- nections inside the switch, be sure that the switch body does not turn during ad- justment.
40 PREP A RA TION Fastener Check • The torque values listed are for assembly and preparation items only , see the appropriate Service Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before retail delivery .
PREP ARA TION 41 T orque No. Fastener N·m kgf·m ft·lb Remarks Steering 1 Handlebar clamp bolts 34 3.5 25 2 Steering stem head nut 88 9.0 65 Brake 3 Front master cylinder clamp bolts 8.8 0.90 78 in·lb S 4 Front caliper mounting bolts (Left and Right) 34 3.
42 PREP A RA TION Standard T orque T able This table relating tightening torque to thread diameter , lists the basic torque for bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent -cleaned threads.
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MODEL APPLICA TION Y ear Model Name 2005 VN1600–D1 VULCAN 1600 NOMAD VN1600 CLASSIC TOURER Part No. 99931-1445-01.
An important point after buying a device Kawasaki 1600 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kawasaki 1600 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kawasaki 1600 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kawasaki 1600 you will learn all the available features of the product, as well as information on its operation. The information that you get Kawasaki 1600 will certainly help you make a decision on the purchase.
If you already are a holder of Kawasaki 1600, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kawasaki 1600.
However, one of the most important roles played by the user manual is to help in solving problems with Kawasaki 1600. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kawasaki 1600 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
