Kawasaki VULCAN 1600 MEAN STREAK - SERVICE Manuals

Manuals and User Guides for KAWASAKI VULCAN 1600 MEAN STREAK - SERVICE. We have 1 KAWASAKI VULCAN 1600 MEAN STREAK - SERVICE manual available for free PDF download: Service Manual

Kawasaki VULCAN 1600 MEAN STREAK - SERVICE Service Manual (609 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 14.25 MB

Emission Control Information 7

How To Use This Manual 9

Before Servicing 12

Model Identification 17

General Specifications 19

Unit Conversion Table 22

Table Of Contents 23

Periodic Maintenance Chart 24

Torque And Locking Agent 26

Specifications 32

Special Tools 34

Periodic Maintenance Procedures 35

Fuel System (DFI) 35

Fuel Hose And Connection Inspection 35

Throttle Control System Inspection 35

Idle Speed Inspection 36

Air Cleaner Element Cleaning 36

Evaporative Emission Control System Inspection(CAL) 37

Periodic Maintenance 37

Cooling System 38

Radiator Hose And Connection Inspection 38

Coolant Change 38

Engine Top End 40

Air Suction Valve Inspection 40

Clutch 41

Clutch Hose And Connection Inspection 41

Clutch Fluid Level Inspection 41

Clutch Fluid Change 42

Clutch Master Cylinder Cup And Dust SealReplacement 43

Clutch Slave Cylinder Piston Seal Replacement 44

Engine Lubrication System 44

Engine Oil Change 44

Oil Filter Replacement 46

Wheels/Tires 46

Tire Inspection 46

Final Drive 47

Oil Level Inspection 47

Oil Change 48

Brakes 49

Brake Pad Wear Inspection 49

Brake Hose And Connection Inspection 49

Brake Fluid Level Inspection 50

Brake Fluid Change 51

Brake Master Cylinder Cup And Dust Seal Replacement 52

Caliper Piston/Dust Seals Replacement 52

Front Brake Light Switch Inspection 52

Rear Brake Light Switch Check/Adjustment 52

Suspension 53

Front Fork Oil Leak Inspection 53

Rear Shock Absorber Oil Leak Inspection 53

Swingarm Pivot Lubrication 53

Steering 54

Stem Bearing Lubrication 54

Steering Check 54

Steering Adjustment 54

Electrical System 55

Spark Plug Cleaning/Inspection 55

General Lubrication 55

Lubrication 55

Nut, Bolt, And Fastener Tightness 56

Tightness Inspection 56

Exploded View 62

DFI Parts Location 66

DFI System 70

DFI Wiring Diagram 72

Specifications 75

Special Tools And Sealant 77

DFI Servicing Precautions 79

Troubleshooting The DFI System 81

Outline 81

Inquiries To Rider 85

DFI System Troubleshooting Guide 88

Poor Running At Low Speed 90

Poor Running Or No Power At High Speed 94

Self-Diagnosis 97

Self-diagnosis Conducting 97

Service Code Reading 99

Service Code Erasing 99

Throttle Sensor (Service Code 11) 103

Throttle Sensor Removal/Adjustment 103

Input Voltage Inspection 103

Output Voltage Inspection 103

Resistance Inspection 104

Inlet Air Pressure Sensor (Service Code 12) 106

Removal 106

Installation 106

Inlet Air Temperature Sensor (Service Code 13) 111

Removal/Installation 111

Sensor Resistance Inspection 112

Water Temperature Sensor (Service Code 14) 113

Atmospheric Pressure Sensor (Service Code 15) 115

Input Voltage Inspection 115

Output Voltage Inspection 116

Crankshaft Sensors (#1, #2: Service Code 21, 22) 119

Crankshaft Sensor Removal/Installation 119

Crankshaft Sensor Inspection 119

Vehicle-down Sensor (Service Code 31) 120

Removal 120

Installation 120

Inspection 120

Fuel Injectors (#1, #2: Service Code 41, 42) 123

Injector Removal 123

Injector Installation 124

Audible Inspection 127

Power Source Voltage Inspection 127

Output Voltage Inspection 128

Injector Signal Test 129

Injector Resistance Inspection 129

Injector Unit Test 130

Fuel Pump (Service Code 45) 131

Fuel Pump Removal 131

Pump Screen, Fuel Filter Cleaning 131

Fuel Pump Installation 132

Operation Inspection 133

Operating Voltage Inspection 134

Ignition Coils (#1, #2: Service Code 51, 52) 136

Removal/Installation 136

Input Voltage Inspection 136

FI Indicator LED Light 137

LED Light Inspection 138

ECU 139

ECU Identification 139

ECU Removal 139

ECU Installation 139

ECU Power Supply Inspection 140

DFI Power Source 141

DFI Fuse Removal 141

DFI Fuse Inspection 141

DFI Main Relay Removal 141

ISC Valves 143

Power Source Voltage Inspection 143

Resistance Inspection 144

Fuel Line 146

Fuel Pressure Inspection 146

Pressure Regulator Removal 148

Fuel Flow Rate Inspection 148

Throttle Grip And Cables 150

Throttle Grip Free Play Inspection 150

Throttle Grip Free Play Adjustment 150

Choke Knob Operation 150

Throttle Body Assy 151

Idle Speed Check 151

Idle Speed Adjustment 151

High Altitude Performance Adjustment 151

Throttle Body Assy Installation 154

Throttle Body Assy Disassembly/Assembly 155

Air Cleaner 158

Air Cleaner Element Removal 158

Air Cleaner Element Cleaning 158

Left Air Cleaner Housing Removal/Installation 158

Right Air Cleaner Housing Removal 159

Right Air Cleaner Housing Installation 159

Lower Air Cleaner Duct Removal/Installation 160

Fuel Tank 161

Fuel Tank Removal 161

Fuel Tank Installation 164

Fuel Tank And Cap Inspection 165

Fuel Tank Cleaning 166

Return Fuel Check Valve Inspection 166

Evaporative Emission Control System 167

Parts Removal/Installation 167

Canister Installation 167

Canister Inspection (Periodic Inspection) 167

Hose Inspection (Periodic Inspection) 168

Separator Operation Test 168

Exploded View 170

Coolant Flow Chart 172

Specifications 174

Special Tools And Sealant 175

Coolant 176

Coolant Deterioration Inspection 176

Coolant Level Inspection 176

Coolant Draining 176

Pressure Testing 177

Cooling System Flushing 177

Water Pump 178

Water Pump Removal 178

Water Pump Installation 178

Water Pump Inspection 179

Mechanical Seal Replacement 179

Radiator 182

Radiator Removal 182

Radiator Installation 183

Radiator Inspection 183

Radiator Cap Inspection 184

Radiator Filler Neck Inspection 184

Thermostat 185

Thermostat Removal 185

Thermostat Installation 185

Thermostat Inspection 185

Hoses And Pipes 186

Hose Installation 186

Hose Inspection 186

Exploded View 188

Specifications 194

Special Tools And Sealant 197

Clean Air System 200

Air Suction Valve Removal 200

Air Suction Valve Installation 200

Air Suction Valve Check 200

Air Switching Valve Removal 201

Air Switching Valve Installation 201

Air Switching Valve Operation Test 201

Air Switching Valve Unit Test 201

Clean Air System Hose Inspection 202

Camshaft Chain Tensioner 203

Camshaft Chain Tensioner Removal 203

Camshaft Chain Tensioner Installation 203

Rocker Case Cover 205

Rocker Case Cover Removal 205

Rocker Case Cover Installation 205

Rocker Case Cover Assembly 206

Rocker Case 207

Rocker Case Removal 207

Rocker Case Installation 208

Rocker Arm Assembly 210

HLA Removal 210

HLA Air Bleeding 210

HLA Installation 211

Camshafts 212

Camshaft Removal 212

Camshaft Installation 212

Camshaft Sprocket Installation 214

Camshaft/Rocker Case Wear 214

Front Camshaft Chain Removal 215

Rear Camshaft Chain Removal 216

KACR Inspection 216

Cylinder Head 218

Cylinder Compression Measurement 218

Cylinder Head Removal 219

Cylinder Head Installation 220

Cylinder Head Warp 220

Valve Clearance Adjustment 221

Valve Removal 221

Valve Installation 221

Valve Guide Removal 221

Valve Guide Installation 222

Valve Guide Wear (Wobble Method) 222

Valve Seat Inspection 223

Valve Seat Repair 223

Cylinders, Piston 227

Cylinder Removal 227

Piston Removal 227

Cylinder, Piston Installation 227

Cylinder Wear 230

Piston Wear 230

Piston/Cylinder Clearance 230

Cylinder Boring And Honing 231

Piston Ring, Piston Ring Groove Wear 231

Piston Ring Groove Width 231

Piston Ring Thickness 232

Piston Ring End Gap 232

Mufflers 233

Exhaust Pipe Removal 233

Lower Muffler Removal 234

Upper Muffler Removal 234

Muffler, Exhaust Pipe Installation 234

Chamber Removal 235

Chamber Installation 235

Chamber Assembly 235

Chamber Identification 236

Exploded View 238

Specifications 240

Special Tools And Sealant 241

Clutch Fluid 242

Clutch Fluid Level Check 242

Clutch Fluid Change 242

Clutch Line Bleeding 242

Clutch Master Cylinder 243

Clutch Lever Adjustment 243

Clutch Master Cylinder Removal 243

Clutch Master Cylinder Installation 243

Clutch Master Cylinder Disassembly/Assembly 244

Clutch Master Cylinder Inspection 244

Clutch Slave Cylinder 245

Clutch Slave Cylinder Removal 245

Clutch Slave Cylinder Installation 245

Clutch Slave Cylinder Disassembly/Assembly 246

6-10 CLUTCH 246

Clutch Cover Removal 247

Clutch Removal 247

Clutch Installation 249

Inner Clutch Hub Disassembly 250

Spring Plate Gap Measurement 250

Spring Plate Gap Adjustment 252

Friction And Steel Plate Wear, And Damage Inspection 252

Friction Or Steel Plate Warp 252

Clutch Spring Height Measurement 253

Clutch Housing Finger Inspection 253

Outer Clutch Hub Spline Inspection 253

Cam Damper Inspection 253

Engine Oil Flow Chart 256

Exploded View 258

Specifications 260

Special Tools And Sealant 261

Engine Oil And Oil Filter 262

Oil Level Inspection 262

Engine Oil Change 262

Oil Filter Replacement 262

Oil Pump And Oil Line 263

Oil Pump Removal 263

Oil Pump Installation 263

Oil Hose Removal 263

Oil Hose Installation 264

Inside Oil Pipe Removal 264

Inside Oil Pipe Installation 265

Blowby Gas System Inspection 267

Breather Drain Cleaning 268

Oil Pressure 269

Oil Pressure Measurement 269

Relief Valve Inspection 270

Exploded View 272

Specifications 274

Engine Removal/Installation 275

Engine Removal 275

Engine Installation 277

Specifications 286

Special Tools And Sealants 288

Crankcase 289

Disassembly 289

Assembly 293

Starter Clutch Disassembly 301

Starter Clutch Assembly 301

Starter Clutch Inspection 301

Starter Torque Limiter Check 302

Crankshaft/Connecting Rods 303

Connecting Rod Removal 303

Connecting Rod Installation 303

Crankshaft/Connecting Rod Cleaning 304

Connecting Rod Bend 304

Connecting Rod Twist 304

Connecting Rod Big End Side Clearance 305

Connecting Rod Big End Bearing Wear 305

Crankshaft Runout 307

Crankshaft Main Bearing/Journal Wear 307

Crankshaft Side Clearance 307

Primary Gear 308

Primary Gear Removal 308

Primary Gear Installation 308

Transmission 310

Shift Pedal Removal 310

Shift Pedal Installation 310

External Shift Mechanism Removal 310

External Shift Mechanism Installation 311

External Shift Mechanism Inspection 311

Transmission Removal 312

Transmission Installation 312

Shift Drum Disassembly/Assembly 313

Transmission Disassembly 314

Transmission Assembly 314

Shift Fork Bending 315

Shift Fork/Gear Groove Wear 315

Shift Fork Guide Pin/Drum Groove Wear 315

Gear Dog And Gear Dog Hole Damage 315

Ball Bearing, Needle Bearing, And Oil Seal 317

Ball Bearing And Outer Race Replacement 317

Ball And Needle Bearing Wear 317

Oil Seal Inspection 318

Exploded View 320

Specifications 322

Special Tools 323

Wheels (Rims) 324

Front Wheel Removal 324

Front Wheel Installation 325

Rear Wheel Removal 326

Rear Wheel Installation 327

Wheel Coupling Removal 328

Wheel Coupling Installation 328

Wheel Inspection 329

Axle Inspection 329

Wheel Balance 329

Balance Inspection 330

Balance Adjustment 330

Balance Weight Removal 331

Balance Weight Installation 331

Tires 333

Air Pressure Inspection/Adjustment 333

Tire Inspection 333

Tire Removal 333

Tire Repair 336

Hub Bearings (Wheel Bearings) 337

Hub Bearings Removal 337

Hub Bearings Installation 337

Hub Bearings Inspection 338

Hub Bearings Lubrication 338

Exploded View 340

Specifications 344

Special Tools 345

Final Gear Case And Oil 347

Oil Level Inspection 347

Oil Change 347

Final Gear Case Removal 347

Final Gear Case Assembly 349

Pinion Gear Removal 351

Pinion Gear Installation 352

Pinion Gear Bearing Preload Adjustment 353

Bevel Gear Inspection 355

Pinion Gear Joint Inspection 355

Final Bevel Gear Adjustment 356

Backlash Adjustment 357

Tooth Contact Adjustment 358

Propeller Shaft 361

Propeller Shaft Removal 361

Propeller Shaft Installation 361

Propeller Shaft Joint Lubrication 362

Propeller Shaft Inspection 362

Sliding Joint Inspection 362

Front Bevel Gears 363

Front Gear Case Removal 363

Front Gear Case Installation 363

Front Gear Case Disassembly 363

Front Gear Case Assembly 365

Driven Gear Disassembly 366

Driven Gear Assembly 366

Damper Cam Removal 367

Damper Cam Installation 367

Front Bevel Gear Adjustment 368

Preload Adjustment 369

Preload Measurement With Spring Scale 370

Backlash Adjustment 371

Tooth Contact Adjustment 372

Bevel Gear Inspection 374

Cam Damper Inspection 374

Bearing And Oil Seal 375

Ball Or Needle Bearing Replacement 375

Ball Bearing Wear 375

Tapered Roller Bearing Inspection 376

Needle Bearing Inspection 376

Oil Seal Inspection 376

Exploded View 378

Specifications 382

Special Tool 383

Brake Lever, Brake Pedal 384

Brake Lever Position Adjustment 384

Brake Pedal Position Adjustment 384

Brake Pedal Removal 385

Brake Pedal Installation 386

Calipers 387

Front Caliper Removal 387

Rear Caliper Removal 387

Caliper Installation 387

Front Caliper Disassembly 388

Front Caliper Assembly 388

Rear Caliper Disassembly 389

Rear Caliper Assembly 390

Caliper Fluid Seal Damage 391

Caliper Dust Seal/Friction Boot Damage 391

Caliper Piston And Cylinder Damage 391

Caliper Holder Shaft Wear 391

Brake Pads 392

Front Brake Pad Removal 392

Front Brake Pad Installation 392

Rear Brake Pad Removal 392

Rear Brake Pad Installation 393

Brake Pad Wear Inspection 393

Master Cylinder 394

Front Master Cylinder Removal 394

Front Master Cylinder Installation 394

Rear Master Cylinder Removal 395

Rear Master Cylinder Installation 396

Front Master Cylinder Disassembly 396

Rear Master Cylinder Disassembly 397

Master Cylinder Assembly 397

Master Cylinder Inspection 398

Brake Discs 399

Brake Disc Removal 399

Brake Disc Installation 399

Brake Disc Wear 399

Brake Fluid 400

Brake Fluid Level Inspection 400

Brake Fluid Change 400

Brake Line Bleeding 400

Brake Hoses 403

Brake Hose Removal/Installation 403

Exploded View 406

Specifications 410

Special Tools 411

Front Fork 412

Fork Oil Change 412

Front Fork Removal (each Fork Leg) 416

Front Fork Installation (each Fork Leg) 417

Front Fork Disassembly 417

Front Fork Assembly 420

Inner Tube, Outer Tube Inspection 421

Dust Seal Inspection 421

Spring Inspection 422

Rear Shock Absorber (Air Type) 423

Rebound Damping Adjustment 423

Air Pressure Adjustment 423

Rear Shock Absorber Removal 425

Rear Shock Absorber Installation 425

Rear Shock Absorber Inspection 425

Scrapping 426

Swingarm 427

Swingarm Removal 427

Swingarm Installation 428

Swingarm Bearing Removal 429

Swingarm Bearing Installation 429

Swingarm Bearing, Sleeve Inspection 429

Grease Seal And Needle Bearing Lubrication 430

Exploded View 432

Special Tools 434

Handlebar 435

Handlebar Removal 435

Handlebar Installation 435

Steering 435

Steering Check 437

Steering Adjustment 437

Steering Stem 438

Steering Stem Removal 438

Steering Stem Installation 440

Steering Stem Warp 441

Steering Stem Bearing 442

Stem Bearing Removal 442

Stem Bearing Installation 442

Stem Bearing Lubrication 443

Stem Cap Deterioration, Damage 443

Exploded View 446

Special Tools 450

Seat 451

Seat Removal 451

Seat Installation 451

Side Covers 452

Left Side Cover Removal 452

Left Side Cover Installation 452

Right Side Cover Removal 452

Fenders 453

Front Fender Removal 453

Rear Fender Removal 453

Rear Fender Installation 453

Battery Case 454

Battery Case Removal 454

Battery Case Installation 454

Tool Box 455

Tool Box Removal 455

Downtube 456

Removal 456

Installation 456

Sidestand 457

Sidestand Installation 457

Rear View Mirrors 458

Rear View Mirror Removal (Other Than European Model) 458

Rear View Mirror Removal (European Model) 458

Rear View Mirror Installation (Other Than European Model) 458

Frame Inspection 460

Electrical Parts Location 463

Exploded View 466

Wiring Diagram (United States Of America And Canada) 472

Wiring Diagram (Other Than United States Of America, Canada And Australia) 474

Wiring Diagram (Australia) 476

Specifications 478

Special Tools And Sealant 480

Servicing Precautions 481

Electrical Wiring 483

Wiring Inspection 483

Battery 484

Battery Removal 484

Battery Installation 484

Electrolyte Filling 485

Initial Charge 487

Precautions 487

Interchange 488

Charging Condition Inspection 488

Refreshing Charge 488

Charging System 490

Alternator Outer Cover Removal 490

Alternator Outer Cover Installation 490

Alternator Cover Removal/Installation 490

Alternator Cover Assembly 491

Alternator Inner Cover Removal 491

Alternator Inner Cover Installation 492

Alternator Rotor Removal 492

Alternator Rotor Installation 492

Alternator Stator Removal 493

Alternator Stator Installation 493

Charging Voltage Inspection 495

Alternator Inspection 495

Regulator/Rectifier Removal 496

Regulator/Rectifier Inspection 497

Ignition System 500

Ignition Coil Removal 502

Ignition Coil Installation 503

Ignition Coil Inspection 503

Spark Plug Removal 504

Spark Plug Installation 504

Spark Plug Cleaning/Inspection 504

Ignition Coil Primary Peak Voltage 505

Crankshaft Sensor Removal 506

Crankshaft Sensor Installation 506

Crankshaft Sensor Inspection 506

Interlock Operation Inspection 508

IC Igniter Inspection 509

Starter Motor 511

Starter Motor Removal 511

Starter Motor Installation 511

Disassembly 512

Assembly 512

Brush Inspection 514

Commutator Cleaning And Inspection 514

Armature Inspection 514

Brush Assy Inspection 515

Brush Plate And Terminal Bolt Inspection 515

Starter Relay Inspection 515

Lighting System 517

Headlight Beam Horizontal Adjustment 517

Headlight Beam Vertical Adjustment 517

Headlight Bulb Replacement 517

Headlight Body Removal 519

City Light Bulb Replacement (other Than US, CA And AU) 519

Tail/Brake Light Bulb Replacement 519

Automatic Turn Signal Canceling System 522

Wiring Inspection 524

Distance Sensor Inspection 524

Turn Signal Switch Inspection 525

Turn Signal Control Relay Inspection 526

Turn Signal Light Bulb Replacement 526

Radiator Fan System 528

Fan System Circuit Inspection 528

Fan Motor Inspection 528

Oil Pressure Warning System 530

Oil Pressure Light Delay Unit Removal 531

Oil Pressure Light Delay Unit Inspection 531

Meter, Gauge 532

Meter Unit Removal 532

Meter Unit Installation 532

Meter Unit Disassemble 533

Meter Unit Assembly 534

Meter Unit Inspection 534

Indicator Panel Bulb Replacement 540

Water Temperature Warning System 543

Water Temperature Warning System Check 543

Switch And Sensors 544

Fuel Reserve Switch Inspection 544

Speed Sensor Removal 544

Speed Sensor Installation 544

Speed Sensor Inspection 545

Front Brake Light Switch Inspection 545

Rear Brake Light Switch Check/Adjustment (Periodic) 545

Switch Inspection 545

Radiator Fan Switch Removal 546

Radiator Fan Switch Installation 546

Radiator Fan Switch Inspection 546

Water Temperature Switch Removal 546

Water Temperature Switch Installation 547

Water Temperature Switch Inspection 547

Diode (Rectifier) Inspection 547

Junction Box 549

Junction Box Fuse Circuit Inspection 549

Starter Circuit/Headlight Relay Inspection 550

Diode Circuit Inspection 550

Fuse 552

Main Fuse Removal 552

Junction Box Fuse Removal 552

Fuse Installation 552

Gear Shifting Faulty 606

Abnormal Engine Noise 606

Over Cooling 606

Clutch Operation Faulty 606

Abnormal Frame Noise 607

Exhaust Smokes Excessively 607

Abnormal Drive Train Noise 607

Battery Trouble 608

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Kawasaki VULCAN 1600 MEAN STREAK - SERVICE Manuals

Manuals and User Guides for KAWASAKI VULCAN 1600 MEAN STREAK - SERVICE. We have 1 KAWASAKI VULCAN 1600 MEAN STREAK - SERVICE manual available for free PDF download: Service Manual

Kawasaki VULCAN 1600 MEAN STREAK - SERVICE Service Manual (609 pages)

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Kawasaki VULCAN 1600 MEAN STREAK - SERVICE Manuals

Manuals and User Guides for KAWASAKI VULCAN 1600 MEAN STREAK - SERVICE. We have 1 KAWASAKI VULCAN 1600 MEAN STREAK - SERVICE manual available for free PDF download: Service Manual

Kawasaki VULCAN 1600 MEAN STREAK - SERVICE Service Manual (609 pages)

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