Kawsaki Vulcan 1600 (03-08) Repair Manual Clymer Reparaturanleitung

CHAPTER 1 / GENERAL INFORMATION

CHAPTER 2 / TROUBLESHOOTING
Starting the engine / Engine does not start / Poor engine performance / Electronic diagnostic system / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Electrical testing / Charging system / Ignition system / Starting system / Final drive / Front suspension and steering / Brake system / Specifications

CHAPTER 3 / LUBRICATION, MAINTENANCE and TUNE-UP
Maintenance schedules / Tune-up / Cylinder identification and firing order / Air filter / Engine compression test / Spark plugs / Ignition timing / Idle speed adjustment / Fuel hose inspection / Fuel pump screen and fuel filter / Throttle cable / Choke cable / Control cable lubrication / Brake and clutch lever lubrication / Clutch / Engine oil and filter / Cooling system / Evaporative emission control systems / Battery / Final drive oil / Drive shaft lubrication / Tires and wheels / Steering bearings / Front suspension check / Rear suspension check / Brakes / Headlight adjustment / Sidestand and ignition cut-off switch test / Engine stop switch check / Front fork oil change / Swing arm bearing lubrication / General lubrication / Fastener inspection / Specifications

CHAPTER 4 / ENGINE TOP END
Rocker case cover / Rocker case / Cam chain tensioner / Camshaft / External oil hoses / Cylinder head / Valves and valve components / Cam chain and chain guide / Cylinder / Piston and piston rings / Specifications

CHAPTER 5 / ENGINE LOWER END
Servicing engine in frame / Engine removal/installation / Shift pedal and shift linkage / External shift mechanism / Front bevel gearcase / Drive gear / Driven gear / Front bevel gear adjustments / Starter gears / Primary drive gear and water pump / drive mechanism / Balancer gears / Crankcase / Crankcase bearings / Crankshaft / Connecting rods / Balancer shaft / Oil pump and oil pressure relief / valve / Break-in / Specifications

CHAPTER 6 / CLUTCH
Clutch bleeding / Clutch fluid draining and flushing / Clutch master cylinder / Clutch slave cylinder / Clutch cover / Clutch / Inner hub / Specifications

CHAPTER 7 / TRANSMISSION and INTERNAL SHIFT MECHANISM
Transmission / Internal gearshift mechanism / Specifications

CHAPTER 8 / FUEL SYSTEM
Digital fuel injection (DFI) / Fuel tank / Fuel return check valve (B and F models) / Fuel pump operation test / Fuel pressure test / Fuel pump discharge test / Fuel pump / Fuel injection main relay / Fuel pressure regulator / Electronic control unit (ECU) / Induction system / Idle speed control (ISC) valves / Fuel injectors / Throttle body and intake manifold / Throttle sensor / Intake air pressure (IAP) sensor / Intake air temperature (IAT) sensor / Water temperature sensor / Atmospheric pressure (AP) sensor / Crankshaft sensors / Vehicle-down sensor / FI indicator / Throttle cable / Choke cable / Clean air system / Evaporative emission control system / Specifications

CHAPTER 9 / ELECTRICAL SYSTEM
Electrical component replacement / Electrical connectors / Battery / Charging system / Regulator/rectifier / Left crankcase outer cover, alternator covers, stator coils, crankshaft sensors and rotor / Ignition system / Peak voltage testing / Ignition coils / Crankshaft sensors / Electronic control unit (ECU) / Ignition timing / Starting system / Starter / Starter relay / Starter circuit relay / Lighting system / Front turn signal housing / Headlight relay / Meter unit / Indicator panel (B and F models) / Turn signal cancelling system / Speed sensor / Fuel level system / Radiator fan / Radiator fan switch / Water temperature switch / Oil pressure light delay unit / Oil pressure switch / Sidestand interlock system test / Switch continuity test / Ignition switch / Front brake light switch / Rear brake light switch / Starter lockout switch / Neutral switch / Sidestand switch / Handlebar switch / Relays / Fuel level indicator light and water temperature warning LED diodes (B and F models) / Fuses and junction box / Color wiring diagrams / Specifications

CHAPTER 10 / COOLING SYSTEM
Cooling system inspection / Radiator / Radiator fan / Coolant reserve tank / Thermostat / Water pump / Specifications

CHAPTER 11 / WHEEL and TIRES
Motorcycle lift / Front wheel / Rear wheel / Front and rear hubs / Rear wheel coupling / Wheel service / Tire service / Wheel balance / Specifications

CHAPTER 12 / FRONT SUSPENSION and STEERING
Handlebar / Handlebar grips / Steering assembly / Steering adjustment / Steering head bearing race / Steering stem bearing / Front fork / Specifications

CHAPTER 13 / REAR SUSPENSION and FINAL DRIVE
Shock absorber / Final drive unit / Swing arm and drive shaft / Specifications

CHAPTER 14 / BRAKES
Brake service notes / Brake bleeding / Brake fluid draining and flushing / Brake pads / Brake caliper removal/installation / Brake caliper overhaul / Front master cylinder / Rear master cylinder / Rear brake pedal and footrest bracket / Brake hoses / Brake disc / Specifications

CHAPTER 15 / BODY and EXHAUST SYSTEM
Rear seat (A, D, E and G models) / Front seat / Side covers / Front footrests / Sidestand / Front fender / Rear fender / Saddlebags (D and G models) / Windshield, sub-windshield and wind deflectors (D and G models) / Front frame guards (D and G models) / Rear frame guards (D and G models) / Backrest and hand grips (D and G models) / Downtube / Exhaust system / Specifications

INDEX

COLOR WIRING DIAGRAMS