Kawasaki Vulcan 1600 Classic, Nomad, Tourer (VN1600) - Repair, Service Manual - Wiring Diagrams

KAWASKI VULCAN 1600 CLASSIC, NOMAD, TOURER (VN1600) - SERVICE MANUAL - REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to motorcycles Kawasaki Vulcan 1600 Classic, Nomad, Tourer (VN1600).


CONTENTS:

- KAWASKI VULCAN 1600 CLASSIC (SERVICE)
- KAWASKI VULCAN 1600 NOMAD, CLASSIC TOURER (SERVICE)
- KAWASKI VULCAN 1600 NOMAD, CLASSIC TOURER (ASSEMBLY)


INDEX:

Foreword
General Information
- Before starting to perform an inspection service or carry out a
- Battery Ground
- Edges of Parts
- Solvent
- Cleaning vehicle before disassembly
- Arrangement and Cleaning of Removed Parts
- Storage of Removed Parts
- Inspection
- Replacement Parts
- Assembly Order
- Tightening Sequence
- Tightening Torque
- Force
- Gasket, O-ring
- Liquid Gasket, Locking Agent
- Press
- Ball Bearing and Needle Bearing
- Oil Seal, Grease Seal
- Circlips, Cotter Pins
- Lubrication
- Direction of Engine Rotation
- Electrical Wires
- VN1600-A1 (US, and Canada) Left Side View:
- VN1600-A1 (US, and Canada) Right Side View:
- VN1600-A1 (Europe) Left Side View:
- VN1600-A1 (Europe) Right Side View:
- Prefixes for Units:
- Units of Temperature:
Periodic Maintenance
- The scheduled maintenance must be done in accordance with this c
- The following tables list the tightening torque for the major fa
- Steering Stem Nut Wrench :
- Fuel System (DFI)
- Fuel Hose and Connection Inspection
- Throttle Control System Inspection
- Idle Speed Inspection
- Air Cleaner Element Cleaning
- Evaporative Emission Control System Inspection (CAL)
- Cooling System
- Engine Top End
- Clutch
- Engine Lubrication System
- Wheel/Tires
- Final Drive
- Brakes
- Suspension
- Steering
- Electrical System
- General Lubrication
- Nut, Bolt, and Fastener Tightness
Fuel System (DFI)
- Terminal Numbers of ECU Connectors
- Oil Pressure Gauge, 5 kgf/cm :
- There are a number of important precautions that should be follo
- Special Tool -
- Torque -
- Outline
- Special Tool -
- Special Tool -
- DFI Diagnosis Flow Chart
- Inquiries to Rider
- NOTE
- Self-diagnosis Procedures
- Service Code Reading
- Service Code Erasing
- Throttle Sensor Removal/Adjustment
- Input Voltage Inspection
- Output Voltage Inspection
- Resistance Inspection
- Removal
- Installation
- Input Voltage Inspection
- Output Voltage Inspection
- Pv = 24 ~ 55 cm Hg
- Pv = 55 ~ 86 cm Hg
- Removal/Installation
- Torque -
- Output Voltage Inspection
- Sensor Resistance Inspection
- Removal/Installation
- Torque -
- Output Voltage Inspection
- Water Temperature Sensor Resistance Inspection
- Removal
- Installation
- Input Voltage Inspection
- Output Voltage Inspection
- Crankshaft Sensor ##1: for Front Cylinder (Service Code 21)
- Crankshaft Sensor Removal/Installation
- Crankshaft Sensor Inspection
- Vehicle-down Sensor Removal
- Installation
- Vehicle-down Sensor Inspection
- Fuel Injector ##1: Front Fuel Injector for Front Cylinder (Servic
- Injector Removal
- Injector Installation
- Audible Inspection
- Power Source Voltage Inspection
- Output Voltage Inspection
- Injector Signal Test
- Injector Resistance Inspection
- Injector Unit Test
- Fuel Pump Removal
- Fuel Pump Installation
- Pressure Regulator Removal
- Pump Screen, Fuel Filter Cleaning
- Operation Inspection
- Operating Voltage Inspection
- Power Source Voltage Inspection
- Operating Voltage Inspection
- Ignition Coil ##1: Ignition Coil for Front Cylinder (Service Code
- Removal/Installation
- Input Voltage Inspection
- Inspection Flow Chart
- LED Light Inspection
- ECU Identification
- ECU Removal
- ECU Installation
- ECU Power Supply Inspection
- DFI Fuse Removal
- DFI Fuse Inspection
- DFI Main Relay Removal
- DFI Main Relay Inspection
- DFI Power Source Circuit
- Removal/Installation
- Power Source Voltage Inspection
- Output Voltage Inspection
- Resistance Inspection
- Fuel Pressure Inspection
- Special Tools -
- Fuel Flow Rate Inspection
- Throttle Grip Free Play Inspection
- Throttle Grip Free Play Adjustment
- Choke Knob Operation
- Choke Cable Free Play Inspection
- Cable Removal/Installation
- Cable Lubrication and Inspection
- Idle Speed Check
- Idle Speed Adjustment
- Throttle Bore Cleaning
- High Altitude Performance Adjustment
- Throttle Body Assy Removal
- Throttle Assy Installation
- Throttle Assy Disassembly/Assembly
- Element Removal
- Element Cleaning
- Left Air Cleaner Housing Removal/Installation
- Right Air Cleaner Housing Removal
- Right Air Cleaner Housing Installation
- Lower Air Cleaner Duct Removal/Installation
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Tank and Cap Inspection
- Fuel Tank Cleaning
- The Evaporative Emission Control System for California Model rou
- Parts Removal/Installation
- Canister Installation
- Canister Inspection (Periodic Inspection)
- Separator Inspection (Periodic Inspection)
- Hose Inspection (Periodic Inspection)
- Separator Operation Test
Cooling System
- Permanent type antifreeze is used as a coolant to protect the co
- Bearing Driver Set :
- Kawasaki Bond (Silicone Sealant) : 56019–120
- Coolant Deterioration Inspection
- Coolant Level Inspection
- Coolant Draining
- Coolant Filling
- Pressure Testing
- Cooling System Flushing
- Water Pump Removal
- Water Pump Installation
- Water Pump Inspection
- Mechanical Seal Replacement
- WARNING
- Radiator Removal
- Radiator Installation
- Radiator Inspection
- Radiator Cap Inspection
- Radiator Filler Neck Inspection
- Thermostat Removal
- Thermostat Installation
- Thermostat Inspection
- Hose Installation
- Torque -
- Hose Inspection
Engine Top End
- Cam Height
- Camshaft Journals and Runout
- Valve Head Thickness
- Valve Stem Bend
- Valve Guide Reamer, 7 : 57001–162
- Air Suction Valve Removal
- Air Suction Valve Installation
- Air Suction Valve Check
- Vacuum Switch Valve Removal
- Vacuum Switch Valve Installation
- Vacuum Switch Valve Operation Test
- Vacuum Switch Valve Unit Test
- Clean Air System Hose Inspection
- Camshaft Chain Tensioner Removal
- Camshaft Chain Tensioner Installation
- Rocker Case Cover Removal
- Rocker Case Cover Installation
- Rocker Case Cover Assembly
- Rocker Case Removal
- Special Tool -
- Rocker Case Installation
- Rocker Arm Assembly
- HLA Removal
- HLA Air Bleeding
- HLA Installation
- Camshaft Removal
- Special Tool -
- Camshaft Installation
- Camshaft Sprocket Installation
- Camshaft/Rocker Case Wear
- Front Camshaft Chain Removal
- Rear Camshaft Chain Removal
- KACR Inspection
- Cylinder Compression Measurement
- Special Tool -
- Special Tools -
- Torque -
- Cylinder Head Removal
- Cylinder Head Installation
- Cylinder Head Warp
- Valve Clearance Adjustment
- Valve Removal
- Valve Installation
- Valve Guide Removal
- Valve Guide Installation
- Valve Guide Wear (Wobble Method)
- Valve Seat Inspection
- Valve Seat Repair
- Cylinder Removal
- Piston Removal
- Cylinder, Piston Installation
- Cylinder Wear
- Piston Wear
- Piston/Cylinder Clearance
- Cylinder Boring and Honing
- Piston Ring, Piston Ring Groove Wear
- Piston Ring Groove Width
- Piston Ring Thickness
- Piston Ring End Gap
- Exhaust Pipe Removal (For other than U.S.A. and Canadian Models)
- Lower Muffler Removal (For other than U.S.A. and Canadian Models
- Upper Muffler Removal (For other than U.S.A. and Canadian Models
- Muffler, Exhaust Pipe Installation (For other than U.S.A. and Ca
- Chamber Removal (For other than U.S.A. and Canadian Models)
- Chamber Installation (For other than U.S.A. and Canadian Models)
- Chamber Assembly (For other than U.S.A. and Canadian Models)
- Chamber Identification (For other than U.S.A. and Canadian Model
- Front Exhaust Pipe Removal (U.S.A. and Canadian Models)
- Rear Exhaust Pipe Removal (U.S.A. and Canadian Models)
- Muffler Removal (U.S.A. and Canadian Models)
- Muffler, Exhaust Pipe Installation (U.S.A. and Canadian Models)
Clutch
- Inside Circlip Pliers :
- Clutch Fluid Level Check
- Clutch Fluid Change
- Clutch Line Bleeding
- Clutch Hose Removal/Installation
- Clutch Hose and Connection Check
- Clutch Lever Adjustment
- Clutch Master Cylinder Removal
- Clutch Master Cylinder Installation
- Clutch Master Cylinder Disassembly/Assembly
- Clutch Master Cylinder Inspection
- Clutch Slave Cylinder Removal
- Clutch Slave Cylinder Installation
- Clutch Slave Cylinder Disassembly/Assembly
- Clutch Cover Removal
- Special Tools -
- Clutch Removal
- Clutch Installation
- Inner Clutch Hub Disassembly
- Spring Plate Gap Measurement
- Spring Plate Gap Adjustment
- Friction and Steel Plate Wear, and Damage Inspection
- Friction or Steel Plate Warp
- Clutch Spring Height Measurement
- Clutch Housing Finger Inspection
- Outer Clutch Hub Spline Inspection
- Cam Damper Inspection
Engine Lubrication System
- Oil Pressure Gauge, 5 kgf/cm :
- WARNING
- Oil Level Inspection
- Engine Oil Change
- Oil Filter Replacement
- Oil Pump Removal
- Oil Pump Installation
- Oil Hose Removal
- Oil Hose Installation
- Inside Oil Pipe Removal
- Inside Oil Pipe Installation
- Blowby Gas System Inspection
- Breather Drain Cleaning
- Oil Pressure Measurement
- Special Tools -
- Torque -
- Relief Valve Inspection
Engine Removal/Installation
- Jack : 57001–1238
- Attachment Jack : 57001–1398
- Engine Removal
- Special Tools -
- Engine Installation
Crankshaft/Transmission
- Outside Circlip Pliers :
- Crankcase Disassembly
- Special Tool -
- Special Tool -
- Special Tool -
- Crankcase Assembly
- Starter Clutch Disassembly
- Starter Clutch Assembly
- Starter Clutch Inspection
- Starter Torque Limiter Check
- Connecting Rod Removal
- Connecting Rod Installation
- Crankshaft/Connecting Rod Cleaning
- Connecting Rod Bend
- Connecting Rod Twist
- Connecting Rod Big End Side Clearance
- Connecting Rod Big End Bearing Wear
- Crankshaft Runout
- Crankshaft Main Bearing/Journal Wear
- Crankshaft Side Clearance
- Primary Gear Removal
- Special Tool -
- Primary Gear Installation
- Shift Pedal Removal
- Shift Pedal Installation
- External Shift Mechanism Removal
- External Shift Mechanism Installation
- External Shift Mechanism Inspection
- Transmission Removal
- Transmission Installation
- Shift Drum Disassembly/Assembly
- Transmission Disassembly
- Transmission Assembly
- Shift Fork Bending
- Shift Fork/Gear Groove Wear
- Shift Fork Guide Pin/Drum Groove Wear
- Gear Dog and Gear Dog Hole Damage
- Ball Bearing and Outer Race Replacement
- Special Tool -
- Ball and Needle Bearing Wear
- Oil Seal Inspection
Wheels/Tires
- Inside Circlip Pliers :
- Front Wheel Removal
- Special Tools -
- Front Wheel Installation
- Rear Wheel Removal
- Rear Wheel Installation
- Wheel Coupling Removal
- Wheel Coupling Installation
- Wheel Inspection
- Axle Inspection
- Wheel Balance
- Balance Inspection
- Balance Adjustment
- Balance Weight Removal
- Balance Weight Installation
- Air Pressure Inspection/Adjustment
- Tire Inspection
- Tire Removal
- Tire Installation
- Tire Repair
- Hub Bearings Removal
- Special Tool -
- Special Tools -
- Hub Bearings Installation
- Hub Bearings Inspection
- Hub Bearings Lubrication
Final Drive
- Bearing Puller :
- Oil Level Inspection
- Oil Change
- Final Gear Case Removal
- Final Gear Case Installation
- Final Gear Case Disassembly
- Final Gear Case
- Backlash-Related Parts
- Correct Tooth Contact Pattern: No adjustment is required.
- Incorrect Tooth Contact Patterns (Example 1)
- Incorrect Tooth Contact Patterns (Example 2)
- Propeller Shaft Removal
- Propeller Shaft Installation
- Propeller Shaft Joint Lubrication
- Propeller Shaft Inspection
- Sliding Joint Inspection
- Front Gear Case Removal
- Front Gear Case Installation
- Front Gear Case Disassembly
- Front Gear Case Assembly
- Driven Gear Disassembly
- Driven Gear Assembly
- Damper Cam Removal
- Damper Cam Installation
- Front Bevel Gear Adjustment
- Front Bevel Gear Adjustment
- Bearing Preloading Mechanism
- Ball or Needle Bearing Replacement
- Special Tools -
- Special Tool -
- Special Tool -
- Ball Bearing Wear
- Tapered Roller Bearing Inspection
- Needle Bearing Inspection
- Oil Seal Inspection
Brakes
- Inside Circlip Pliers :
- Brake Lever Position Adjustment
- Brake Pedal Position Adjustment
- Brake Pedal Removal
- Brake Pedal Installation
- Front Caliper Removal
- Rear Caliper Removal
- Caliper Installation
- Front Caliper Disassembly
- Front Caliper Assembly
- Rear Caliper Disassembly
- Rear Caliper Assembly
- Caliper Fluid Seal Damage
- Caliper Dust Boot and Friction Boot Damage
- Caliper Piston and Cylinder Damage
- Caliper Holder Shaft Wear
- Front Brake Pad Removal
- Front Brake Pad Installation
- Rear Brake Pad Removal
- Rear Brake Pad Installation
- Brake Pad Wear Inspection
- Front Master Cylinder Removal
- Front Master Cylinder Installation
- Rear Master Cylinder Removal
- Rear Master Cylinder Installation
- Front Master Cylinder Disassembly
- Rear Master Cylinder Disassembly
- Master Cylinder Assembly
- Master Cylinder Inspection
- Brake Disc Removal
- Brake Disc Installation
- Brake Disc Wear
- Brake Disc Warp
- Brake Fluid Level Inspection
- Brake Fluid Change
- Brake Line Bleeding
- Brake Hose Removal/Installation
- Torque -
Suspension
- Fork Cylinder Holder Handle :
- Fork Oil Change
- Special Tool -
- Torque -
- Front Fork Removal
- Front Fork Installation
- Disassembly
- Assembly
- Inner Tube, Outer Tube Inspection
- Dust Seal Inspection
- Spring Tension
- Rebound Damping Adjustment
- Spring Preload Adjustment
- Rear Shock Absorber Removal
- Rear Shock Absorber Installation
- Rear Shock Absorber Inspection
- Swingarm Removal
- Special Tools -
- Swingarm Installation
- Swingarm Bearing Removal
- Swingarm Bearing Installation
- Swingarm Bearing, Sleeve Inspection
- Grease Seal and Needle Bearing Lubrication
Steering
- Head Pipe Outer Race Press Shaft :
- Handlebar Removal
- Handlebar Installation
- Steering Check
- Steering Adjustment
- Steering Stem Removal
- Special Tools -
- Steering Stem Installation
- Steering Stem Warp
- Stem Bearing Removal
- Special Tool -
- Stem Bearing Installation
- Stem Bearing Lubrication
- Stem Cap Deterioration, Damage
Frame
- Jack :
- Rear Seat Removal
- Rear Seat Installation
- Front Seat Removal
- Front Seat Installation
- Left Side Cover Removal
- Left Side Cover Installation
- Right Side Cover Removal/Installation
- Front Fender Removal
- Rear Fender Removal
- Battery Case Removal
- Tool Box Removal
- Footboard Removal
- Footboard Disassembly
- Sidestand Installation
- Downtube Removal
- Special Tools -
- Downtube Installation
- Frame Inspection
Electrical System
- Spark Plug Wrench, Hex 18 :
- Left Handlebar Switches [A]
- There are a number of important precautions that should be follo
- Wiring Inspection
- Special Tool -
- Battery Removal
- Battery Installation
- Electrolyte Filling
- Initial Charge
- Precautions
- Interchange
- Alternator Outer Cover Removal
- Alternator Outer Cover Installation
- Alternator Cover Removal/Installation
- Alternator Cover Assembly
- Alternator Inner Cover Removal
- Alternator Inner Cover Installation
- Alternator Rotor Removal
- Alternator Rotor Installation
- Alternator Outside Stator Removal
- Alternator Outside Stator Installation
- Alternator Inside Stator Removal
- Alternator Inside Stator Installation
- Charging Voltage Inspection
- Alternator Inspection
- Regulator/Rectifier Removal
- Regulator/Rectifier Installation
- Rectifier Inspection
- Regulator Inspection
- Charging System Circuit
- Ignition System Circuit
- Starter Motor Removal
- Starter Motor Installation
- Starter Motor Disassembly
- Starter Motor Assembly
- Brush Inspection
- Commutator Cleaning and Inspection
- Armature Inspection
- Brush Assy Inspection
- Brush Plate and Terminal Bolt Inspection
- Starter Relay Inspection
- Electric Starter Circuit
- This model adopts the daylight system and has a headlight relay
- Headlight Beam Horizontal Adjustment
- Headlight Beam Vertical Adjustment
- Headlight Bulb Replacement
- Headlight Body Removal
- City Light Bulb Replacement (other than US, CA and AU)
- Tail/Brake Light Bulb Replacement
- Headlight/Tail Light Circuit
- Automobiles use a turn signal canceling system actuated by steer
- Wiring Inspection
- Distance Sensor Inspection
- Turn Signal Switch Inspection
- Turn Signal Switch Connections
- Turn Signal Control Relay Inspection
- Turn Signal Light Bulb Replacement
- Turn Signal Cancelling System Circuit
- WARNING
- Fan System Circuit Inspection
- Fan Motor Inspection
- Radiator Fan Circuit
- Motorcycle operation with low engine oil level, even if it is hi
- Oil Pressure Warning System Circuit
- Oil Pressure Light Delay Unit Removal
- Oil Pressure Light Delay Unit Inspection
- Meter Unit Removal
- Meter Unit Installation
- Meter Unit Disassembly
- Meter Unit Assembly
- Meter Unit Inspection
- LED Light Inspection
- Indicator Light Inspection
- Meter Unit Circuit
- Water Temperature Warning System Check
- Fuel Level Sensor Inspection
- Special Tool -
- Torque -
- Fuel Reserve Switch Inspection
- Speed Sensor Removal
- Speed Sensor Installation
- Speed Sensor Inspection
- Front Brake Light Switch Inspection
- Rear Brake Light Switch Check/Adjustment
- Radiator Fan Switch Removal
- Radiator Fan Switch Installation
- Radiator Fan Switch Inspection
- Water Temperature Switch Removal
- Water Temperature Switch Installation
- Water Temperature Switch Inspection
- Switch Inspection
- Rear Brake Light Switch Connections
- Side Stand Switch Connections
- Neutral Switch Connections
- Oil Pressure Switch Connections*
- The junction box [A] has fuses [B], relays, and diodes. The rela
- Junction Box Fuse Circuit Inspection
- Starter Circuit/Headlight Relay Inspection
- Diode Circuit Inspection
- Junction Box Internal Circuit
- Main Fuse Removal
- Junction Box Fuse Removal
- Fuse Installation
- Fuse Inspection
Appendix
- NOTE
- Engine Doesn't Start, Starting Difficulty:
- Poor Running at Low Speed:
- Poor Running or No Power at High Speed:
- Overheating:
- Over Cooling:
- Clutch Operation Faulty:
- Gear Shifting Faulty:
- Abnormal Engine Noise:
- Abnormal Drive Train Noise:
- Abnormal Frame Noise:
- Oil Pressure Warning Light Goes On:
- Exhaust Smokes Excessively:
- Handling and/or Stability Unsatisfactory:
- Brake Doesn't Hold:
- Battery Trouble: