Kawasaki 1600 manual

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. Good setup pro- cedures can prev[...]

T able of Contents Un crating ...................................................................................... 3 Opening Crate ............................................................................. 3 Parts Check ................................................................................. 4 As sembly ...............................[...]

[...]

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. CAUTION When you remove the crate bracket from the motorcycle, be careful not to drop any p[...]

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 = 88.5 Screw , Switch Housing, LH & [...]

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 ector 3 (US) (CN) only Reflector 1 (AUS) only Cap Nut, Reflector 3 D = 5, (US)(CN) only Cap Nut, Reflector 1 D = 5, (AUS) only Cap Nut, Black, License Pl[...]

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). A. Front Bolts B. Slanted Side C. Gap D. Punched Mark E. No Gap F [...]

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 . • Apply silicone grease or PBC greas[...]

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). • Position the master cylinder so that the gap between the front and rear master cylinder clamps aligns with the punched mark on the handle[...]

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. F. Throttle Cables G. Brake Hose H. Right Switch Lead I. Handlebar Front Fender Front Reflector[...]

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 . A. Front Brake Calipers B. Flanged Bol[...]

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. A. Front Axle B. Collar (Right) C. Axle Clamp Bolts (Right) D. Co[...]

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. The brake will not func- tion on the first application of the lever if this is not done. Front [...]

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. Front Footboard (Left) B. B olt (Rear) NOTE ż The bolt in front is for tightening the footboard [...]

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. A. Helmet Lock B. Ignition Key C. Projection D. Screw E. Rear Guard (Left) Rear Guard[...]

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. Label T op D. 20 mm (0.8 in.) E. Label For CN Models (56070-1 180) NOTE ż Reinstal[...]

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 . • Screw the rear view mirror in completely , and then back it[...]

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 . A. Stay B. Mirror • Inst[...]

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. Clamps Deflectors (Left and Right) Installation • Assemble the left and right sta ys, deflectors[...]

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). A. Rear Fender B. License Plate Bracket C. Bolts (D = 6, L = 12) Rear Reflectors and License Plate Holder US and CN Models only • Assemble the rear reflector[...]

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. A. License Plate Holder B. Bolt (D = 6, L = 14) C. Cap Nut D. License Plate Brack[...]

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. Left Saddlebag Dampers Installation • Insert[...]

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. Insert one or two flat washer(s) between the upper damper and the [...]

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 . Insufficient or incorrect electrolyte will reduc[...]

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. Harness (Fuel Pump) M. Harness (Fuel Gauge) • Remove the 15 A fuse holder from the battery[...]

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. NOTE ż Do not tilt the electrolyte container . • Check the electrolyte flow .[...]

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. Re-check voltage and if less t[...]

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. Battery E. 4 P Connector (Diagnosis) F . 6 P Connector (Rear Harness) G. Plastic Cla[...]

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. Lower Level Line • If the fluid level in the reservoir is lower than the low[...]

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 . This bleeds the ai[...]

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. • Also check for fluid leakage around the fit- tings. Rear B rake Line Air Bleeding • Remove the rear brake reservoir cap and di- aphragm, and check that there is p[...]

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. Clutch Line Air Bleeding • Loosen the mounting bolts to remove the al- ternator o[...]

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. The numbers on the adjuster show the setting po- sition. STD Rebound Damping Force: No. 2 pos[...]

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. A. Cap B. F (Full) Mark C. L (Low) Mark • Install the cap. • T o install the r[...]

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. Use the same type of oil that is alr[...]

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 (0.21 US qt) Final Gear Case Oil D rain Plug T o rque: 8.8 N·m (0.90 kgf·m, 78 in·lb) A. Oil Drai[...]

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. Horizontal Adjustment • Tu r n t h e horizontal adjusting screw on the headlight ri[...]

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 . Also check to see that each cotter pin or circlip is in place.[...]

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 3.5 25 5 Front brake bleed valves (Left and Right) 7.8 0.80 69 in·lb 6 Rear master cylinder [...]

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. General Fasteners: Threads T orque dia. mm N·m kgf?[...]

[...]

MODEL APPLICA TION Y ear Model Name 2005 VN1600–D1 VULCAN 1600 NOMAD VN1600 CLASSIC TOURER Part No. 99931-1445-01[...]