Kawasaki VN 1500 Drifter Manuals

Manuals and User Guides for Kawasaki VN 1500 Drifter. We have 1 Kawasaki VN 1500 Drifter manual available for free PDF download: Service Manual

Kawasaki VN 1500 Drifter Service Manual (482 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 158.45 MB

Quick Reference Guide. Contents 2

List Of Abbreviations 4

General Information. Table Of Contents 6

Before Servicing 7

Model Identification 9

Motorcycle View 9

General Specifications 11

Periodic Maintenance Chart 13

Torque And Locking Agent 14

Special Tools And Sealant 19

Cable, Wire And Hose Routing 25

Evaporative Emission Control System (California Model) 48

Fuel System (DFI). Table Of Contents 51

Fuel System (DFI) 52

Fuel System (DFI) Specifications 53

DFI Parts Location 54

Fuel System Exploded View 56

DFI System 60

DFI Wiring Diagram 62

Terminal Numbers Of ECU Connectors 63

Terminal Names 63

DFI And Electrical Parts 63

FDI Servicing Precautions 64

Throttle Grip And Cables 66

Throttle Grip Free Play Inspection/Adjustment 66

Throttle Cable Removal/Installation 66

Throttle Cable Lubrication And Inspection 67

Choke Knob Operation 67

Choke Cable Free Play Inspection 67

Choke Cable Removal/Installation/Lubrication/Inspection 67

Throttle Assy 68

Idle Speed Inspection 68

Throttle Bore Cleaning 68

High Altitude Performance Adjustment 69

Throttle Assy Removal 69

Throttle Assy Installation 72

Air Cleaner 75

Rlement Removal 75

Element Cleaning And Inspection 75

Left Air Cleaner Housing Removal/Installation 75

Right Air Cleaner Housing Removal 76

Right Air Cleaner Housing Installation 76

Lower Air Cleaner Duct Removal 77

Fuel Tank 78

Fuel Tank Removal 78

Fuel Tank Installation 81

Fuel Tank And Cap Inspection 81

Fuel Tank Cleaning 82

Return Fuel Check Valve Inspection 82

Evaporative Emission Control System 83

Canister Inspection 83

Hose Inspection 83

Separator Inspection 83

Separator Emission Control System 84

Troubleshooting The DFI System 85

DFI Diagnosis Flow Chart 88

Problem Chart 90

Idling Stability 91

Driveability 91

Engine Doesn't Stop 91

Sample Diagnosis Sheet 93

ECU Removal 94

ECU Installation 94

ECU Power Supply Inspection 95

ECU Grounding Inspection 95

DFI Power Source Circuit 96

DFI Powr Source 97

DFI Fuse Removal 97

DFI Fuse Installation 97

DFI Fuse Inspection 97

DFI Main Relay Inspection 98

FI Indicator LED Light 99

Inspection Flow Chart 99

LED Light Inspection 100

ISC Valves 101

ISC Valves Removal/Installation 102

Power Source Voltage Inspection 102

Output Voltage Inspection 103

Resistance Inspection 104

ISC Valves Schematic Diagram 105

Fuel Line 106

Fuel Pressure Inspection 106

Pressure Regulator Removal 107

Fuel Flow Rate Inspection 107

Self-Diagnosis Function 109

Self-Diagnosis Procedure 109

How To Read Fault Codes 111

How To Erase Fault Codes 111

Fault Code Table 112

Backups By ECU 113

Throttle Sensor Removal/Adjustment 114

Input Voltage Inspection 114

Throttle Sensor. Output Voltage Inspection 115

Throttle Sensor. Resistance Inspection 116

Throttle Sensor. Schematic Diagram 117

Vacuum Sensor Removal/Installation 118

Vacuum Sensor. Input Voltage Inspection 118

Vacuum Sensor. Output Voltage Inspection 119

Inlet Air Temperature Sensor Removal/Installation 124

Inlet Air Temperature Sensor. Output Voltage Inspection 124

Inlet Air Temperature Sensor Resistance Inspection 125

Water Temperature Sensor Removal/Installation 126

Water Temperature Sensor. Output Voltage Inspection 126

Water Temperature Sensor Resistance Inspection 127

Atmospheric Pressure Sensor Removal/Installation 128

Atmospheric Pressure Sensor Input Voltage Inspection 128

Atmospheric Pressure Sensor Output Voltage Inspection 129

Pickup Coil Removal/Installation 132

Pickup Coil Inspection 132

Vehicle-Down Sensor 133

Vehicle-Down Sensor Removal 133

Vehicle-Down Sensor Installation 134

Vehicle-Down Sensor Inspection 134

Vehicle-Down Sensor Schematic Diagram 136

Fuel Injector Removal 137

Fuel Injector Installation 138

Fuel Injector Power Source Voltage Inspection 139

Fuel Injector Output Voltage Inspecton 140

Fuel Injector Audible Inspection 141

Fuel Injector Signal Test 141

Fuel Injector Resistance Inspection 142

Fuel Injector Unit Test 142

Fuel Injectors Schematic Diagram 143

In-Tank Fuel Pump Removal 144

Pump Screen Cleaning 144

Fuel Pump Installation 145

In-Tank Fuel Pump Operation Inspection 146

In-Tank Fuel Pump Operating Voltage Inspection 146

In-Tank Fuel Pump Power Source Voltage Inspection 147

Sealing Of Fuel Pump Connector Schematic Diagram 148

Ignition Coils Removal/Installation 149

Ignition Coils Input Voltage Inspection 149

Ignition Coils Schematic Diagram 150

Cooling System. Table Of Contents 151

Cooling System Exploded View 152

Coolant Flow Chart 154

Cooling System Specifications 156

Coolant Deterioration Inspection 157

Coolant Level Inspection 157

Coolant Draining 157

Coolant Filling 158

Coolant Pressure Testing 160

Cooling System Flushing 161

Water Pump Removal 162

Water Pump Installation 162

Water Pump Inspection 163

Mechanical Seal Replacement 163

Radiator Removal 165

Radiator Installation 165

Radiator Inspection 166

Radiator Filler Neck Inspection 167

Thermostat Removal 168

Thermostat Installation 168

Thermostat Inspection 168

Hose 169

Engine Top End. Table Of Contents 170

Engine Top End Exploded View 171

Engine Top End Specifications 174

Clean Air System 177

Air Suction Valve Removal 177

Air Suction Valve Installation 177

Air Suction Valve Inspection 177

Vacuum Switch Valve Removal/Installation 178

Vacuum Switch Valve Operation Test 178

Clean Air System Hose Inspection 179

Camshaft Chain Tensioner 180

Rocker Case Cover 182

Rocker Case 183

Rocker Arm Assembly 185

HLA (Hydraulic Lash Adjuster) 186

Camshafts 187

Camshaft Sprocket Installation 189

Camshaft/Rocker Case Wear 189

Camshaft Chains Removal/Wear 190

KACR (Kawasaki Automatic Compression Release) 191

Cylinder Head 193

Engine Top End Valves 195

Valve Guide Installation 196

Valve-to-Guide Clearance Measurement 196

Valve Seat Inspection 196

Valve Seat Repair 197

Valve Seat Repair Diagram 200

Cylinders, Piston 201

Piston Ring 205

Muffler 206

Silencer Removal/Installation 207

Clutch. Table Of Contents 208

Clutch Exploded View 209

Clutch Specifications 210

Clutch Lever 211

Clutch Fluid 212

Clutch Master Cylinder 214

Clutch Slave Cylinder 216

Clutch Cover Removal 218

Spring Plate Gap Measurement 221

Friction And Steel Plate Wear, And Damage Inspection 223

Friction Or Steel Plate Warp 223

Clutch Spring Height Measurement 223

Clutch Housing Finger Inspection/Hub Spline Inspection 223

Cam Damper Inspection 224

Engine Lubrication System. Table Of Contents 225

Engine Oil Flow Chart 226

Engine Lubrication System Exploded View 228

Engine Lubrication System Specifications 229

Engine Oil And Oil Filter 230

Oil Pump 232

Oil Hoses And Pipes 233

Oil Pressure 237

Engine Removal/Installation. Table Of Contents 238

Engine Removal/Installation Exploded View 239

Engine Removal/Installation Specifications 240

Engine Removal 241

Engine Installation 243

Crankshaft/Transmission. Table Of Contents 245

Crankshaft/Transmission Exploded View 246

Crankshaft/Transmission Specifications 250

Crankcase 251

Crankshaft/Connecting Rods 260

Starter Clutch 266

Starter Torque Limiter 268

Water Pump Idle Shaft Holder 269

Primary Gear 270

Transmission 271

Transmission Disassembly/Assembly 275

Drive Shaft 276

Output Shaft 277

Ball Bearing, Needle Bearing, And Oil Seal 279

Wheels/Tires. Table Of Contents 280

Wheels/Tires Exploded View 281

Wheels/Tires Specifications 282

Wheels (Rims) 283

Wheel Coupling Removal/Installation 286

Rim Inspection 287

Axle Inspection 287

Wheel Balance 287

Balance Adjustment 288

Air Pressure Inspection/Adjustment 288

Tire Inspection 289

Tire Removal 289

Tire Installation 290

Hub Bearings (Wheel Bearings) 292

Hub Bearings (Wheel Bearings) Removal/Installation 292

Final Drive. Table Of Contents 294

Final Drive Exploded View 295

Final Drive Specifications 298

Final Gear Case Oil 299

Final Gear Case 302

Final Bevel Gear Adjustment 304

Tooth Contact Adjustment 306

Correct/Incorrect Tooth Contact Patterns 307

Propeller Shaft 308

Front Bevel Gears 310

Driven Gear Assembly 313

Damper Cam Removal 313

Damper Cam Installation 314

Front Bevel Gear Adjustment 314

Backlash-Related Parts 314

Collars For Preload Adjustment 316

Spacers For Preload Adjustment 316

Bearing Preloading Mechanism 316

Backlash Adjustment 317

Shims For Drive Gears 317

Front Bevel Gears: Tooth Contact Adjustment 318

Bearing And Oil Seal 320

Brakes. Table Of Contents 322

Brakes Exploded View 323

Brakes Specifications 326

Brake Lever, Brake Pedal 327

Calipers 330

Brake Pads 334

Master Cylinder 335

Brake Discs 338

Brake Fluid 339

Brake Hoses 343

Suspension. Table Of Contents 344

Suspension Exploded View 345

Suspension Specifications 348

Front Fork 349

Rear Shock Absorber (Air Type) 356

Reboud Damping Adjustment 356

Air Pressure Adjustment 356

Swingarm 360

Steering. Table Of Contents 363

Steering Exploded View 364

Steering Specifications 365

Handlebar 366

Steering 368

Steering Stem 369

Steering Stem Bearing 373

Frame. Table Of Contents 375

Frame Exploded View 376

Frame Specifications 379

Seat 380

Side Covers 381

Fenders 383

Battery Case 384

Tool Box 385

Downtube 386

Front Footboard, Sidestand 387

Frame 388

Electrical System. Table Of Contents 389

Electrical Parts Location 391

Electrical System Wiring Diagram 392

Electrical System Exploded View 398

Electrical System Specifications 404

Electrical System Servicing Precautions 406

Electrical Wiring 407

Battery 408

Electrolyte Filling 409

Refreshing Charge 412

Charging System 413

Alternator Outer Cover 413

Alternator Cover Assembly 414

Alternator Inner Cover Removal 414

Alternator Rotor 415

Alternator Stator 416

Charging Voltage Inspection 417

Regulator/Rectifier 418

Regulator/Rectifier Connectors 420

Charging System Schematic Diagram 421

Ignition System Circuit 422

Ignition System Troubleshooting 423

Ignition System 424

Ignition Coil 425

Spark Plug 426

Ignition Timing Inspection 427

Pickup Coil 428

IC Igniter 429

IC Igniter In ECU Troubleshooting 430

Starter Motor 431

Brush Inspection 434

Commutator Cleaning And Inspection 434

Armature Inspection 434

Brush Wire Inspection 435

Brush Plate And Terminal Bolt Inspection 435

Starter Relay Inspection 435

Electric Starter Circuit 436

Lighting System 437

Headlight Beam Adjustment 437

Headlight Bulb Replacement 437

Headlight Body Removal 438

Tail/Brake Light Bulb Replacement 439

Headlight Circuit 440

Automatic Turn Signal Cancelling System 441

Turn Signal Switch 443

Turn Signal Control Unit 443

Turn Signal Light Bulb Replacement 444

Radiator Fan System 445

Fan System Circuit 445

Fan Motor 445

Oil Pressure Warning System 446

Meter, Gauge 448

Clock Setting 451

LCD Segment Inspection 452

Speedometer Inspection 453

Speed Sensor Power Supply Inspection 453

ODO Meter Inspection 453

TRIP Meter Inspection 454

Fuel Level Gauge Inspection 454

Distance Sensor Inspection 454

LED And Indicator Lights Inspection 455

Meter, Gauge Schematic Diagram 458

Fuel Gauge Operation Inspection 460

Fuel Gauge Circuit 460

Switch And Sensors 461

Fuel Reserve Switch Inspection 461

Speed Sensor Removal/Installation 461

Speed Sensor 462

Front Brake Light Switch 462

Rear Brake Light Switch 462

Radiator Fan Switch 463

Water Temperature Switch 463

Fuel Level Sensor 464

Diode (Rectifier) 465

Junction Box Fuse Circuit 466

Starter Circuit/Headlight Realy 466

Diode Circuit Inspection 467

Junction Box Internal Circuit 468

Fuse 469

Main Fuse Removal 469

Junction Box Fuse Removal 469

Fuse Installation/Inspection 469

Appendix. Table Of Contents 470

Additional Considerations For Racing 471

Spark Plug Inspection 473

Troubleshooting Guide (except DFI) 474

Engine Doesn't Start 474

Poor Running At Low Speed 474

Poor Running Or No Power At High Speed 475

Overheating 475

Overcooling 475

Clutch Operation Faulty 475

Gear Shifting Faulty 476

Abnormal Engine Noise 476

Abnormal Drive Train Noise 476

Abnormal Frame Noise 476

Oil Pressure Warning Light Goes On 477

Exhaust Smokes Excessively 477

Handling And/Or Stability Unsatisfactory 477

Brake Doesn't Hold 477

Battery Trouble 478

General Lubrication 479

Nut, Bolt And Fastener Tightness 480

Unit Conversion Table 481

Table Of Contents 482

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Kawasaki VN 1500 Drifter Manuals

Manuals and User Guides for Kawasaki VN 1500 Drifter. We have 1 Kawasaki VN 1500 Drifter manual available for free PDF download: Service Manual

Kawasaki VN 1500 Drifter Service Manual (482 pages)

Table of contents

Related Products

Kawasaki Categories

Kawasaki VN 1500 Drifter Manuals

Manuals and User Guides for Kawasaki VN 1500 Drifter. We have 1 Kawasaki VN 1500 Drifter manual available for free PDF download: Service Manual

Kawasaki VN 1500 Drifter Service Manual (482 pages)

Table of contents

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Related Products

Kawasaki Categories