Kawasaki VN1500A Manuals

Manuals and User Guides for Kawasaki VN1500A. We have 2 Kawasaki VN1500A manuals available for free PDF download: Service Manual

Kawasaki VN1500A Service Manual (270 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 61.81 MB

List Of Abbreviations 4

How To Use This Manual 7

General Information 9

Table Of Contents 9

Before Servicing 10

1.2 GENERAL INFORMATION 10

Model Ldentification 12

VN1500-A1 Right Side View 12

VN1500-B1 Left Side View 12

General Specifications 13

Periodic Maintenance Chart (Other Than US And Canada) 15

Periodic Maintenance Chart (US And Canada) 16

Torque And Locking Agent 17

General Fasteners Table 20

Cable, Wire And Hose Routing 21

Wiring Routing Diagram 21

Cable, Hose And Wire Routing Diagram 22

Carburetor Hose Routing Diagram 23

Hose Routing Diagram 24

Evaporative Emission Control System Hose Routing Diagrams 25

Engine Top End Hose Routing Diagram 27

Fuel System 28

Fuel System Exploded View 29

Evaporative Emission Control System (California Model) Diagram 31

Fuel System Specifications 32

Fuel System - Special Tools 32

Throttle Grip And Cables 33

Throttle Cable Adjustment 33

Throttle Grip Free Play 33

Idle Speed Adjustment 34

High Altitude Performance Adjustment (US Model) 34

Fuel System Cleanliness Inspection 34

Carburetor Synchronization 35

Vacuum Hose Fitting View 35

Service Fuel Level Adjustment 35

Carburetor Removal 36

Fuel Level Adjustment - Diagram 36

Carburetor I Nstallation 37

Carburetor Separation 38

Carburetor Combination 38

Rear Carburetor Choke Rod Pivot Screw Choke Link Rod View 38

Throttle Link Rod Cotter Pin And Plastic Washer View 38

Carburetor Disasembly 39

Garburetor Assembly 39

Plug Installation 40

Fuel Pump Removal 41

Carbu Retor I Nspection 41

Fuel Pump Installation Notes 42

Fuel Filter Removal 42

Air Cleaner Element (Housing) Removal 42

Lnstallation Notes 42

Element Clearing 43

Air Cleaner Housing Installation 43

Air Cleaner Duct Lnstallation 44

Surge Tank Removal 44

Hose Inspection (Periodic) 44

Separator Inspection 44

Separator Operation Test 45

Canister Inspection 45

Evaporative Emission Control System Diagram 45

Cooling System 46

Cooling System Exploded View 47

E X P L O D E D V I E 47

Cooling System Specifications 48

Coolant Flow Chart 48

Coolant Level Inspection 49

Coolant Draining 49

Coolant Filling 50

Water And Coolant Mixture Ratio (Recommended) 50

Pressure Testing 51

Water Pump - Visual Leak Inspection 51

Water Pump, Mechanical Seal Removal 51

Impeller Bolt 52

Radiator And Cooling Fan 52

Water Pump, Mechanical Seal Lnstallation 52

Removal 52

Radiator Cover View 53

Radiator Upper Bolt View 53

Fan Switch Connector View 53

Lift And Right Top Tube Covers 53

Radiator Lnspection 54

Radiator Hoses View 54

Fan Mounting Bolts View 54

Radiator Cap Inspection 54

Thermostat Removal 55

Radiator Cap Relief Pressure 55

Cooling Hoses (LH And Lower) View 55

Thermostat Installation 56

Thermostat Inspection 56

Thermostat Valve Opening Temperature 56

Thermostatic Fan Switch Removal 57

Thermostatic Fan Switch Installation 57

Engine Top End 58

Engine Top End Exploded View 59

Engine Top End Specifications 63

Engine Top End - Special Tools 64

Clean Air System (US And Switzerland Models) 65

Air Suction Valve Inspection 65

Vacuum Switch Valve Test 65

Camshaft Chain Tensioner Removal 65

Camshaft Chain Tensioner Installation 66

Rocker Case Cap Removal 67

Rocker Case Cap Installation 67

Rocker Shafts, Rocker Arms, Rocker Case Removal 67

Rocker Shafts, Rocker Arms, Rocker Case Installation 68

Removal 68

Lnstallation Note 68

Engine Top End 69

HLA Removal 69

HLA Air Bleeding 69

HLA (Hydraulic Lash Adjuster) 69

HLA Inspection 70

Camshafts Removal 70

Camshafts Installation (Including Chain Timing Procedure) 70

Front Cylinder 70

Rear Cylinder 71

Camshaft Sprocket Assembly 71

Camshaft, Rocker Case Wear 71

KACR (Kawasaki Automatic Compression Release) Removal 72

KACR (Kawasaki Automatic Compression Release) Installation 72

KACR (Kawasaki Automatic Compression Release) Inspection 72

Camshaft Chain Wear 72

Cylinder Head 73

Cylinder Compression Measurement 73

Cylinder Removal 74

Cylinder Installation 74

Valves 74

Valve Clearance Adjustment 74

Valve Removal 76

Valve Installation 76

Valve Guide Removal 76

Valve Guide Installation 76

Valve Face Contact Inspection 77

Valve Seat Outside Diameter 77

Valve Seat Width Inspection 77

Valve Seat Repair (Valve Lapping) 77

Seat Cutter Operating Care 78

Marks Stamped On The Cutter 78

Seat Cutter - Operating Procedures 78

Measuring Valve-to-Guide Clearance (Wobble Method) 79

Cylinders, Pistons 80

Piston Removal 81

Piston Installation 81

Cylinder Wear 82

Piston Wear 82

Piston Ring, Piston Ring Groove Wear 82

Piston Ring End Gap 82

Muffler Removal (for VN1500-A) 83

Front Exhaust Pipe Cover View 83

Muffler Installation 84

Muffler Removal (for VN1500-B) 84

Muffler Installation (for VN1500-B) 85

Clutch 86

Clutch Exploded View 87

Clutch Specifications 88

Clutch - Special Tool 88

Clutch Fluid Level Inspection 89

Recommended Clutch Fluid 89

Clutch Fluid Changing 89

Master Cylinder Installation 90

Master Cylinder Disassembly 90

Bleeding The Clutch Line 90

Clutch Slave Cylinder Removal 91

Clutch Slave Cylinder Installation 91

Master Cylinder Assembly 91

Master Cylinder Inspection 91

Clutch Slave Cylinder Disassembly 92

Clutch Slave Cylinder Assembly 92

Clutch Removal 92

Clutch Installation 93

Clutch Inner Hub Disassembly/Assembly 94

Spring Plate Free Play Measurement 95

Spring Plate Free Play Adjustment 95

Friction And Steel Plate Damage, Wear 95

Friction And Steel Plate Warp Inspection 95

Cluth Housing Finger Inspection 96

Clutch Hub Spline Inspection 96

Cam Damper Inspection 96

Clutch Spring Height Measurement 96

Engine Lubrication System 97

Engine Lubrication Exploded View 98

Engine Oil Flow Chart 100

Engine Lubrication System Specifications 102

Engine Lubrication System - Special Tools 102

Engine Oil And Oil Filter 103

Oil Level Inspection 103

Engine Oil Change 103

Oil Filter Change 103

Oil Pump Screen Cleaning 104

Oil Pump Removal 104

Oil Pump Installation 105

Oil Pipes Removal 105

Oil Pipes Installation 106

Oil Pressure Measurement 106

Engine Removal/Installation 108

Engine Removal/Installation - Exploded View 109

Engine Removal/Installation - Special Tools 109

Engine Removal 110

Starter Motor Wire Terminal View 111

Alternator And Pickup Coil Wire Connectors Ground Wire Terminal View 111

Throttle Cable Adjuster View 111

Oil Pressure Switch Wire Terminal, Neutral Switch Wire Terminal View 111

Engine Installation 113

Lnstallation 113

Crankshaft/Transmission 114

Crankshaft/Transmission Exploded View 115

Crankshaft/Transmission Specifications 119

Crankshaft/Transmission - Special Tools 120

Crankcase Splitting 121

Crankcase 122

Crankcase Assembly 124

Liquid Gasket Applied Area View 125

Crankcase Replacement 127

Crankshaft/Connesting Rods 128

Crankhaft Installation 128

Connecting Rod Removal 128

Connecting Rod Installation 128

Connecting Rod Big End Bearing Insert/Crankpin Wear 129

Connecting Rod Removal . & 1 129

Connecting Rod Lnstallation & 1 129

Crankshaft Runout 130

Crankshaft Main Bearing/Main Journal Wear 130

Crankshaft Side Clearance 131

Left Engine Cover Removal 132

Starter Motor Clutch Removal 132

Right Engine Cover 8 - 1 132

Starter Motor Clutch Installation 133

Starter Motor Clutch Disassembly 133

Starter Motor Clutch Assembly 133

Lnstallation 133

LH Balancer Weight Removal 134

Starter Motor Clutch Inspection 134

R H B A L A N C E R W E I G H T R E M O V A 134

LH Balancer Weight Installation 135

Balancer Shaft Removal 135

Balancer Shaft Installation 135

R H B A L A N C E R W E I G H T L N S T A L L A T I O 135

Starter Torque Limiter Removal 136

Starter Torque Limiter Inspection 136

Water Pump Idle Shaft Holder Removal 136

Water Pump Idle Shaft Holder Installation 136

Primary Gear Removal 137

Primary Gear Installation 137

Transmission 138

External Shift Mechanism Removal 138

External Shift Mechanism Installation 138

External Shift Mechanism Inspection 139

Transmission Shafts Removal 140

Transmission Shafts Installation 140

Transmission Disassembly 140

Transmission Assembly 140

Drive Shaft Diagram 141

Output Shaft Diagram 142

Shift Drum Removal 142

Shift Drum Disassembly/Assembly 142

Wheels/Tires 144

R E M O V A 144

Wheels/Tires Exploded View 145

Wheels/Tires Specifications 147

Wheels/Tires - Special Tools 148

Wheels (Rims) 149

Front Wheel Removal 149

Front Wheel Installation 149

Rear Wheel Remowal 150

Rear Wheel Installation 150

Wheel Coupling Removal 151

Wheel Coupling Installation 151

Wheel (Rim) Inspection (for Cast Wheel) 151

Balance Weight Lnstallation 152

Balance Weight Removal 152

Spoke Inspection (for Wire-spoke Wheel) 153

Rim Inspection 153

Balance Weight Installation 153

Tire Air Pressure Inspection 154

Tire Inspection 154

Tire Removal 154

Tire Installation 155

Air Valve View 155

Hub Bearings Removal 155

Hub Bearings Installation 156

Hub Bearings Lubrication 156

Speedometer Gear Housing Disassembly And Assembly 156

Speedometer Gear Housing Lubrication 157

Final Drive 158

Final Drive Exploded View 159

Final Drive Specifications 161

Final Drive - Special Tools 161

Final Gear Case Oil 163

Final Gear Oil Level Inspection 163

Final Gear Oil Change 163

Final Gear Case Removal 163

Final Gear Case - Installation Notes 164

Final Gear Case Disassembly 164

Final Gear Case Diagram 165

Final Gear Case - Assembly Notes 166

Bevel Gear Inspection 167

Pinion Gear Joint Inspection 167

Ball Bearing Inspection 167

Needle Bearing Inspection, Oil Seal Inspection 167

Final Bevel Gear Adjustment 168

Backlash-Related Parts Diagram 168

Ring Gear Shims For Backlash Adjustment 168

Pinion Gear Shims For Tooth Contact Adjustment 168

Backlash Adjustment 169

Correct Tooth Contact Pattern 169

Tooth Contact Adjustment 169

Incorrect Tooth Contact Patterns 170

Propeller Shaft Removal 171

Pinion Gear Bearing Inspection 171

Oil Seal Inspection 171

Propeller Shaft - Installation Notes 172

Sliding Joint Lubrication 172

Propeller Shaft Inspection 172

Sliding Joint Inspection 172

Front Bevel Gears 173

Front Gear Case Removal 173

Front Gear Case Installation 173

Front Gear Case Disassembly (including Drive Gear Removal) 173

Front Gear Case Assembly (including Drive Gear Installation) 175

Driven Gear Assembly 175

Damper Cam Removal 176

Damper Cam Installation Notes 177

Front Bevel Gear Adjustment 177

Preload Adjustment 178

Collars For Preload Adjustment 178

Spacers For Preload Adjustment 178

Bearing Preloading Mechanism Diagram 179

Shims For Drive Gear 180

Shims For Driven Gear 180

Final Drive Information 181

Tapered Roller Bearing Inspection 182

Needle Bearing Inspection 182

Brakes 183

Brakes Exploded View 184

Brakes Specifications 186

Brakes - Special Tool 186

Brake Pedal Position Adjustment 187

Front Caliper Removal 187

Rear Caliper Removal 188

Caliper Installation 188

Brake Pads Removal 188

Front Master Cylinder Installation 189

Rear Master Cylinder Removal 189

Lining Wear 189

Rear Master Cylinder Installation 190

Rear Master Cylinder Inspection And Adjustment 190

Rear Mastery Cylinder Disassembly 190

Rear Master Cylinder Assembly 190

Brake Disc Wear 191

Brake Disc Warp 191

Brake Fluid Level Inspection 191

Rear/front Brake Fluid Reservoirs Views 191

Brake Fluid Change 192

Bleeding The Brake Line 192

Suspension 194

Suspension Exploded View 195

Suspension Specifications 197

Suspension - Special Tools 197

Front Fork Oil Change (each Fork Leg) 198

Front Fork Removal (each Fork Leg) 199

Front Fork Installation (each Fork Leg) 199

Front Fork Disassembly 199

Front Fork Assembly 200

Inner Tube Inspection 201

Guide Bush Inspection 201

Oil Seal And Dust Seal Inspection 201

Spring Tension 201

Rear Shock Absorber Adjustment 202

Rear Shock Absorber Removal 202

Rear Shock Absorber - Installation Notes 202

Rear Shock Absorber Wear 202

Swing Arm Removal 203

Swing Arm Installation 203

Bushing Wear 203

Grease Seal And Needle Bearing Removal/Assembly 203

Grease Seal And Needle Bearing Lubrication 204

Sleeve And Needle Bearing Wear 204

Steering 205

Steering Exploded View 206

Steering - Special Tools 207

Steering Adjustment 208

Steering Stem Removal 208

Steering Installation 210

Bearing Lubrication 211

Frame 212

Frame Exploded View 213

Right Down Tube Removal (To Access Right Engine Cover) 216

Rear Fender Rear Section Removal 216

Right Footpeg Removal 217

Rear Fender Front Section Removal 217

Right Footpeg Installation 218

Electrical System 219

Electrical System - Precautions 220

VN 1500-A1~A8/B1~B6 Wiring Diagram (US And Canada) 221

Electrical System Parts Location 222

Electrical System Exploded View 223

Electrical System Specifications 227

Electrical System - Special Tools 228

Battery 229

Electrolyte Level Inspection 229

Electrolyte Specific Gravity Inspection 229

Initial Charging 229

Battery Ordinary Charging 230

Battery Charging Rate/Time (12V 20Ah) 230

Alternator Rotor Removal 230

Alternator Rotor Installation 231

Alternator Stator Removal 231

Alternator Stator Installation 232

Alternator Inspection 232

Alternator Output Voltage Table 232

Stator Coil Resistance Table 232

Rectifier Circuit Inspection Table 233

Regulator Inspection 233

Charging System Wiring Diagram 234

Ignition System 235

Pickup Coil Removal 235

Pickup Coil Installation 235

Regulator/Rectifier Output Voltage Inspection 235

Pickup Coil Inspection 236

Ignition Coil Removal 236

Ignition Coil Inspection 238

Spark Plug Gap 238

Ignition Circuit 239

IC Igniter Troubleshooting 240

Starter Motor Removal 241

Filter Installation Note 241

IC Igniter Inspection 241

Starter Motor Installation 242

Starter Motor Disassembly (To Remove The Brushes) 242

Starter Motor Assembly 243

Brush Inspection 244

Commutator Cleaning And Inspection 244

Armature Inspection 244

Negative Brush And Lead Assembly Inspection 244

Electric Starter Circuit 245

Positive Brush And Lead Assembly Inspection 246

Starter Relay Inspection 246

Headlight Beam Horizontal Adjustment 246

Headlight Beam Vertical Adjustment 246

Headlight Removal 247

Bulb Replacement Notes 247

Reserve Lighting System Inspection 248

Headlight Circuit (US And Canada) 248

Reserve Lighting System Operation 249

Fuel Pump 249

Fuel Pump Circuit 249

Fuel Pump Internal Resistance 250

Fuel Pump Operates Check 250

Cooling Fan System Circuit Inspection 250

Fan Inspection, Fan Relay Inspection 250

Meter, Gauge 251

Speedometer Removal 251

Cooling Fan Circuit 251

Bulb Replacement (Meter And Indicator Lights) 252

Fuel Gauge Operation Inspection (VN 15000-A) 252

Fuel Level Sensor Inspection (VN 1500-A) 252

Switches And Sensors 253

Rear Brake Light Switch Adjustment 253

Fuel Gauge Circuit (VN 1500-A1) 253

Junction Box And Main Fuse 254

Fuse Removal (Junction Box) 254

Fan Switch Inspection 254

Fuse Installation 255

Main Fuse Removal 255

Fuse Inspection 255

Junction Box Fuse Circuit Inspection 255

Diode Circuit Inspection 256

Relay Circuit Inspection (with The Battery Disconnected) 256

Relay Circuit Inspection (with The Battery Connected) 256

Junction Box Internal Circuit 256

VN 15OO-A2~A8/B2~86 Wiring Diagram (Orher Than US And Canada 257

VN 15OO-A9~Wiring Diagram (US And Canada) 259

Appendix 261

Additional Considerations For Racing 262

Spark Plug View 262

Spark Plug Inspection 262

Spark Plug Condition 263

Plug Reach 263

Troubleshooting Guide 264

Engine Doesn't Start, Starting Difficulty 264

Poor Running Or At Low Speed 264

Poor Running Or No Power At High Speed 265

Overheating 265

Over Cooling 265

Clutch Operation Faulty 265

Gear Shifting Faulty 266

Abnormal Engine Noise 266

Abnormal Drive Train Noise 266

Oil Pressure Warning Light Goes On 266

Handling And/or Stability Unsatisfactory 267

Brake Doesnt Hold 267

Battery Discharged 267

Attery Overcharged 267

General Lubrication 268

Nut, Bolt, And Fasener Tightness 268

Unit Conversion Table 269

T R A N S M I S S I O N A S S E M B L 269

S H I F T D R U M R E M O V A 269

Model Application Table 270

Kawasaki VN1500A Service Manual (12 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 2.09 MB

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Kawasaki VN1500A Manuals

Manuals and User Guides for Kawasaki VN1500A. We have 2 Kawasaki VN1500A manuals available for free PDF download: Service Manual

Kawasaki VN1500A Service Manual (270 pages)

Table of contents

Kawasaki VN1500A Service Manual (12 pages)

Related Products

Kawasaki Categories

Kawasaki VN1500A Manuals

Manuals and User Guides for Kawasaki VN1500A. We have 2 Kawasaki VN1500A manuals available for free PDF download: Service Manual

Kawasaki VN1500A Service Manual (270 pages)

Table of contents

Kawasaki VN1500A Service Manual (12 pages)

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