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KAWASAKI Manuals
Motorcycle
VN1600 MEAN STREAK - SERVICE
Service manual
KAWASAKI VN1600 MEAN STREAK Service Manual Page 33
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Also See for VN1600 MEAN STREAK
Installation instructions
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Page
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609
Go
Page 1
Page 2
Page 3
Page 4
Page 5
Page 6
Page 7 - Emission control information
Page 8
Page 9 - How to use this manual
Page 10
Page 11
Page 12 - Before Servicing
Page 13
Page 14
Page 15
Page 16
Page 17 - Model Identification
Page 18
Page 19 - General Specifications
Page 20
Page 21
Page 22 - Unit Conversion Table
Page 23 - Table Of Contents
Page 24 - Periodic Maintenance Chart
Page 25
Page 26 - Torque and Locking Agent
Page 27 - Torque and locking agent
Page 28
Page 29
Page 30
Page 31
Page 32 - Specifications
Page 33
Page 34 - Special Tools
Page 35 - Periodic Maintenance Procedures
Page 36 - Idle Speed Inspection
Page 37 - Evaporative Emission Control System Insp...
Page 38 - Cooling System
Page 39
Page 40 - Engine Top End
Page 41 - Clutch
Page 42 - Clutch Fluid Change
Page 43 - Clutch Master Cylinder Cup and Dust Seal...
Page 44 - Clutch Slave Cylinder Piston Seal Replac...
Page 45
Page 46 - Oil Filter Replacement
Page 47 - Final Drive
Page 48 - Oil Change
Page 49 - Brakes
Page 50 - Brake Fluid Level Inspection
Page 51 - Brake Fluid Change
Page 52 - Brake Master Cylinder Cup and Dust Seal ...
Page 53 - Suspension
Page 54 - Steering
Page 55 - Electrical System
Page 56 - Nut, Bolt, and Fastener Tightness
Page 57
Page 58
Page 59
Page 60
Page 61
Page 62 - Exploded View
Page 63
Page 64
Page 65
Page 66 - DFI Parts Location
Page 67
Page 68
Page 69
Page 70 - DFI System
Page 71
Page 72 - DFI Wiring Diagram
Page 73
Page 74
Page 75 - Specifications
Page 76
Page 77 - Special Tools and Sealant
Page 78
Page 79 - DFI Servicing Precautions
Page 80
Page 81 - Troubleshooting the DFI System
Page 82
Page 83
Page 84
Page 85 - Inquiries to Rider
Page 86
Page 87
Page 88 - DFI System Troubleshooting Guide
Page 89
Page 90 - Poor running at low speed
Page 91
Page 92
Page 93
Page 94 - Poor running or no power at high speed
Page 95
Page 96
Page 97 - Self-Diagnosis
Page 98
Page 99 - Service Code Reading
Page 100
Page 101
Page 102
Page 103 - Throttle Sensor (Service Code 11)
Page 104 - Resistance Inspection
Page 105
Page 106 - Inlet Air Pressure Sensor (Service Code ...
Page 107 - Output Voltage Inspection
Page 108
Page 109
Page 110
Page 111 - Inlet Air Temperature Sensor (Service Co...
Page 112 - Sensor Resistance Inspection
Page 113 - Water Temperature Sensor (Service Code 1...
Page 114 - Sensor Resistance Inspection
Page 115 - Atmospheric Pressure Sensor (Service Cod...
Page 116 - Output Voltage Inspection
Page 117
Page 118
Page 119 - Crankshaft Sensors (#1, #2: Service Code...
Page 120 - Vehicle-down Sensor (Service Code 31)
Page 121
Page 122
Page 123 - Fuel Injectors (#1, #2: Service Code 41,...
Page 124 - Injector Installation
Page 125
Page 126
Page 127 - Audible Inspection
Page 128 - Output Voltage Inspection
Page 129 - Injector Signal Test
Page 130 - Injector Unit Test
Page 131 - Fuel Pump (Service Code 45)
Page 132 - Fuel Pump Installation
Page 133 - Operation Inspection
Page 134 - Operating Voltage Inspection
Page 135
Page 136 - Ignition Coils (#1, #2: Service Code 51,...
Page 137 - FI Indicator LED Light
Page 138 - LED Light Inspection
Page 139 - ECU
Page 140 - ECU Power Supply Inspection
Page 141 - DFI Power Source
Page 142
Page 143 - ISC Valves
Page 144 - Resistance Inspection
Page 145
Page 146 - Fuel Line
Page 147
Page 148 - Pressure Regulator Removal
Page 149
Page 150 - Throttle Grip and Cables
Page 151 - Throttle Body Assy
Page 152
Page 153
Page 154 - Throttle Body Assy Installation
Page 155 - Throttle Body Assy Disassembly/Assembly
Page 156
Page 157
Page 158 - Air Cleaner
Page 159 - Right Air Cleaner Housing Removal
Page 160 - Lower Air Cleaner Duct Removal/Installat...
Page 161 - Fuel Tank
Page 162
Page 163
Page 164 - Fuel Tank Installation
Page 165 - Fuel Tank and Cap Inspection
Page 166 - Fuel Tank Cleaning
Page 167 - Evaporative Emission Control System
Page 168 - Hose Inspection (Periodic Inspection)
Page 169
Page 170 - Exploded View
Page 171
Page 172 - Coolant Flow Chart
Page 173
Page 174 - Specifications
Page 175 - Special Tools and Sealant
Page 176 - Coolant
Page 177 - Pressure Testing
Page 178 - Water Pump
Page 179 - Water Pump Inspection
Page 180
Page 181
Page 182 - Radiator
Page 183 - Radiator Installation
Page 184 - Radiator Cap Inspection
Page 185 - Thermostat
Page 186 - Hoses and Pipes
Page 187
Page 188 - Exploded View
Page 189
Page 190
Page 191
Page 192
Page 193
Page 194 - Specifications
Page 195
Page 196
Page 197 - Special Tools and Sealant
Page 198
Page 199
Page 200 - Clean Air System
Page 201 - Air Switching Valve Removal
Page 202 - Clean Air System Hose Inspection
Page 203 - Camshaft Chain Tensioner
Page 204
Page 205 - Rocker Case Cover
Page 206 - Rocker Case Cover Assembly
Page 207 - Rocker Case
Page 208 - Rocker Case Installation
Page 209
Page 210 - Rocker Arm Assembly
Page 211 - HLA Installation
Page 212 - Camshafts
Page 213
Page 214 - Camshaft Sprocket Installation
Page 215 - Front Camshaft Chain Removal
Page 216 - Rear Camshaft Chain Removal
Page 217
Page 218 - Cylinder Head
Page 219 - Cylinder Head Removal
Page 220 - Cylinder Head Installation
Page 221 - Valve Clearance Adjustment
Page 222 - Valve Guide Installation
Page 223 - Valve Seat Inspection
Page 224
Page 225
Page 226
Page 227 - Cylinders, Piston
Page 228
Page 229
Page 230 - Cylinder Wear
Page 231 - Cylinder Boring and Honing
Page 232 - Piston Ring Thickness
Page 233 - Mufflers
Page 234 - Lower Muffler Removal
Page 235 - Chamber Removal
Page 236 - Chamber Identification
Page 237
Page 238 - Exploded View
Page 239
Page 240 - Specifications
Page 241 - Special Tools and Sealant
Page 242 - Clutch Fluid
Page 243 - Clutch Master Cylinder
Page 244 - Clutch Master Cylinder Disassembly/Assem...
Page 245 - Clutch Slave Cylinder
Page 246 - Clutch Slave Cylinder Disassembly/Assemb...
Page 247 - Clutch Cover Removal
Page 248
Page 249 - Clutch Installation
Page 250 - Inner Clutch Hub Disassembly
Page 251
Page 252 - Spring Plate Gap Adjustment
Page 253 - Clutch Spring Height Measurement
Page 254
Page 255
Page 256 - Engine Oil Flow Chart
Page 257
Page 258 - Exploded View
Page 259
Page 260 - Specifications
Page 261 - Special Tools and Sealant
Page 262 - Engine Oil and Oil Filter
Page 263 - Oil Pump and Oil Line
Page 264 - Oil Hose Installation
Page 265 - Inside Oil Pipe Installation
Page 266
Page 267 - Blowby Gas System Inspection
Page 268 - Breather Drain Cleaning
Page 269 - Oil Pressure
Page 270 - Relief Valve Inspection
Page 271
Page 272 - Exploded View
Page 273
Page 274 - Specifications
Page 275 - Engine Removal/Installation
Page 276
Page 277 - Engine Installation
Page 278
Page 279
Page 280
Page 281
Page 282 - Exploded View
Page 283
Page 284
Page 285
Page 286 - Specifications
Page 287
Page 288 - Special Tools and Sealants
Page 289 - Crankcase
Page 290
Page 291
Page 292
Page 293 - Assembly
Page 294
Page 295
Page 296
Page 297
Page 298
Page 299
Page 300
Page 301 - Starter Clutch Disassembly
Page 302 - Starter Torque Limiter Check
Page 303 - Crankshaft/Connecting Rods
Page 304 - Crankshaft/Connecting Rod Cleaning
Page 305 - Connecting Rod Big End Side Clearance
Page 306
Page 307 - Crankshaft Runout
Page 308 - Primary Gear
Page 309
Page 310 - Transmission
Page 311 - External Shift Mechanism Installation
Page 312 - Transmission Removal
Page 313 - Shift Drum Disassembly/Assembly
Page 314 - Transmission Disassembly
Page 315 - Shift Fork Bending
Page 316
Page 317 - Ball Bearing, Needle Bearing, and Oil Se...
Page 318 - Oil Seal Inspection
Page 319
Page 320 - Exploded View
Page 321
Page 322 - Specifications
Page 323 - Special Tools
Page 324 - Wheels (Rims)
Page 325 - Front Wheel Installation
Page 326 - Rear Wheel Removal
Page 327 - Rear Wheel Installation
Page 328 - Wheel Coupling Removal
Page 329 - Wheel Inspection
Page 330 - Balance Inspection
Page 331 - Balance Weight Removal
Page 332
Page 333 - Tires
Page 334
Page 335
Page 336 - Tire Repair
Page 337 - Hub Bearings (Wheel Bearings)
Page 338 - Hub Bearings Inspection
Page 339
Page 340 - Exploded View
Page 341
Page 342
Page 343
Page 344 - Specifications
Page 345 - Special Tools
Page 346
Page 347 - Final Gear Case and Oil
Page 348
Page 349 - Final Gear Case Assembly
Page 350
Page 351 - Pinion Gear Removal
Page 352 - Pinion Gear Installation
Page 353 - Pinion Gear Bearing Preload Adjustment
Page 354
Page 355 - Bevel Gear Inspection
Page 356 - Final Bevel Gear Adjustment
Page 357 - Backlash Adjustment
Page 358 - Tooth Contact Adjustment
Page 359
Page 360
Page 361 - Propeller Shaft
Page 362 - Propeller Shaft Joint Lubrication
Page 363 - Front Bevel Gears
Page 364
Page 365 - Front Gear Case Assembly
Page 366 - Driven Gear Disassembly
Page 367 - Damper Cam Removal
Page 368 - Front Bevel Gear Adjustment
Page 369 - Preload Adjustment
Page 370 - Preload Measurement with Spring Scale
Page 371 - Backlash Adjustment
Page 372 - Tooth Contact Adjustment
Page 373
Page 374 - Bevel Gear Inspection
Page 375 - Bearing and Oil Seal
Page 376 - Tapered Roller Bearing Inspection
Page 377
Page 378 - Exploded View
Page 379
Page 380
Page 381
Page 382 - Specifications
Page 383 - Special Tool
Page 384 - Brake Lever, Brake Pedal
Page 385 - Brake Pedal Removal
Page 386 - Brake Pedal Installation
Page 387 - Calipers
Page 388 - Front Caliper Disassembly
Page 389 - Rear Caliper Disassembly
Page 390 - Rear Caliper Assembly
Page 391 - Caliper Fluid Seal Damage
Page 392 - Brake Pads
Page 393 - Rear Brake Pad Installation
Page 394 - Master Cylinder
Page 395 - Rear Master Cylinder Removal
Page 396 - Rear Master Cylinder Installation
Page 397 - Rear Master Cylinder Disassembly
Page 398 - Master Cylinder Inspection
Page 399 - Brake Discs
Page 400 - Brake Fluid
Page 401
Page 402
Page 403 - Brake Hoses
Page 404
Page 405
Page 406 - Exploded View
Page 407
Page 408
Page 409
Page 410 - Specifications
Page 411 - Special Tools
Page 412 - Front Fork
Page 413
Page 414
Page 415
Page 416 - Front Fork Removal (each fork leg)
Page 417 - Front Fork Installation (each fork leg)
Page 418
Page 419
Page 420 - Front Fork Assembly
Page 421 - Inner Tube, Outer Tube Inspection
Page 422 - Spring Inspection
Page 423 - Rear Shock Absorber (Air Type)
Page 424
Page 425 - Rear Shock Absorber Removal
Page 426 - Scrapping
Page 427 - Swingarm
Page 428 - Swingarm Installation
Page 429 - Swingarm Bearing Removal
Page 430 - Grease Seal and Needle Bearing Lubricati...
Page 431
Page 432 - Exploded View
Page 433
Page 434 - Special Tools
Page 435 - Handlebar
Page 436
Page 437 - Steering Check
Page 438 - Steering Stem
Page 439
Page 440 - Steering Stem Installation
Page 441 - Steering Stem Warp
Page 442 - Steering Stem Bearing
Page 443 - Stem Bearing Lubrication
Page 444
Page 445
Page 446 - Exploded View
Page 447
Page 448
Page 449
Page 450 - Special Tools
Page 451 - Seat
Page 452 - Side Covers
Page 453 - Fenders
Page 454 - Battery Case
Page 455 - Tool Box
Page 456 - Downtube
Page 457 - Sidestand
Page 458 - Rear View Mirrors
Page 459
Page 460 - Frame Inspection
Page 461
Page 462
Page 463 - Electrical Parts Location
Page 464
Page 465
Page 466 - Exploded View
Page 467
Page 468
Page 469
Page 470
Page 471
Page 472 - Wiring Diagram (United States of America...
Page 473
Page 474 - Wiring Diagram (Other Than United States...
Page 475
Page 476 - Wiring Diagram (Australia)
Page 477
Page 478 - Specifications
Page 479
Page 480 - Special Tools and Sealant
Page 481 - Servicing Precautions
Page 482
Page 483 - Electrical Wiring
Page 484 - Battery
Page 485 - Electrolyte Filling
Page 486
Page 487 - Initial Charge
Page 488 - Interchange
Page 489
Page 490 - Charging System
Page 491 - Alternator Cover Assembly
Page 492 - Alternator Inner Cover Installation
Page 493 - Alternator Stator Removal
Page 494
Page 495 - Charging Voltage Inspection
Page 496 - Regulator/Rectifier Removal
Page 497 - Regulator/Rectifier Inspection
Page 498
Page 499
Page 500 - Ignition System
Page 501
Page 502 - Ignition Coil Removal
Page 503 - Ignition Coil Installation
Page 504 - Spark Plug Removal
Page 505 - Ignition Coil Primary Peak Voltage
Page 506 - Crankshaft Sensor Removal
Page 507
Page 508 - Interlock Operation Inspection
Page 509 - IC Igniter Inspection
Page 510
Page 511 - Starter Motor
Page 512 - Disassembly
Page 513
Page 514 - Brush Inspection
Page 515 - Brush Assy Inspection
Page 516
Page 517 - Lighting System
Page 518
Page 519 - Headlight Body Removal
Page 520
Page 521
Page 522 - Automatic Turn Signal Canceling System
Page 523
Page 524 - Wiring Inspection
Page 525 - Turn Signal Switch Inspection
Page 526 - Turn Signal Control Relay Inspection
Page 527
Page 528 - Radiator Fan System
Page 529
Page 530 - Oil Pressure Warning System
Page 531 - Oil Pressure Light Delay Unit Removal
Page 532 - Meter, Gauge
Page 533 - Meter Unit Disassemble
Page 534 - Meter Unit Assembly
Page 535
Page 536
Page 537
Page 538
Page 539
Page 540 - Indicator Panel Bulb Replacement
Page 541
Page 542
Page 543 - Water Temperature Warning System
Page 544 - Switch and Sensors
Page 545 - Speed Sensor Inspection
Page 546 - Radiator Fan Switch Removal
Page 547 - Water Temperature Switch Installation
Page 548
Page 549 - Junction Box
Page 550 - Starter Circuit/Headlight Relay Inspecti...
Page 551
Page 552 - Fuse
Page 553
Page 554
Page 555
Page 556
Page 557
Page 558
Page 559
Page 560
Page 561
Page 562
Page 563
Page 564
Page 565
Page 566
Page 567
Page 568
Page 569
Page 570
Page 571
Page 572
Page 573
Page 574
Page 575
Page 576
Page 577
Page 578
Page 579
Page 580
Page 581
Page 582
Page 583
Page 584
Page 585
Page 586
Page 587
Page 588
Page 589
Page 590
Page 591
Page 592
Page 593
Page 594
Page 595
Page 596
Page 597
Page 598
Page 599
Page 600
Page 601
Page 602
Page 603
Page 604
Page 605
Page 606 - Gear shifting faulty
Page 607 - Abnormal frame noise
Page 608 - Battery trouble
Page 609
/
609
Contents
Table of contents
Troubleshooting
Bookmarks
Advertisement
Specifications
Item
Final Drive:
Final gear case oil:
Grade
Viscosity
Oil level
Amount
Propeller shaft joint grease
Brakes:
Brake fluid
Grade
Brake pad lining thickness:
Front
Rear
Brake light timing:
Front
Rear
Electrical System:
Spark plug gap
AT: Republic of Austria
CH: Swiss Confederation
DE: Federal Republic of Germany
Standard
API Service Classification: GL-5
hypoid gear oil
when above 5°C (41°F) SAE90
when below 5°C (41°F) SAE80
Filler opening bottom
200 mL (6.76 US oz)
20 mL (0.68 US oz),
high-temperature grease
DOT4
4.0 mm (0.12 in.)
7.5 mm (0.295 in.)
Pulled ON
ON after about 10 mm (0.39 in.) of pedal
travel
0.8
0.9 mm (0.031
PERIODIC MAINTENANCE 2-11
0.035 in.)
Service Limit
– – –
– – –
– – –
– – –
– – –
– – –
1 mm (0.04 in.)
1 mm (0.04 in.)
– – –
– – –
– – –
Table of
Contents
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Show quick links
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Specifications
Wheel Coupling Removal/Installation
Emission control information
Before Servicing
Oil Filter Replacement
Tire Inspection
Unit Conversion Table
Periodic Maintenance Chart
Rear Wheel Installation
Engine Oil Change
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Chapters
Table Of Contents
11
Periodic Maintenance
23
Fuel System (dfi)
59
Cooling System
169
Engine Top End
187
Clutch
237
Engine Lubrication System
255
7-16 Engine Lubrication System
271
Crankshaft/transmission
281
Wheels/tires
319
Final Drive
339
Brakes
377
Suspension
405
Steering
431
Frame
445
Electrical System
461
Table of Contents
Troubleshooting
Troubleshooting the DFI System
81
DFI System Troubleshooting Guide
88
Also See for KAWASAKI VN1600 MEAN STREAK
Kawasaki K99990-059A Installation Instructions
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This manual is also suitable for:
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Latest comments:
Sebastian
Dec 08, 2016 07:15:
Manual vulcan 2006 para mantenimiento cambio de aceite etc
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