Kawasaki 1600 User Manual

VULCAN 1600 NOMADVN1600 CLASSIC TOURERMotorcycleAssembly & PreparationManual

8 ASSEMBLYAssemblyHandlebarNOTEżPosition the handlebar clamp on the handle-bar with the slanted side facing rearward.•Set the handlebar to match its p

ASSEMBLY9A. Right Switch HousingB. Screws (L = 25)C. HarnessD. Throttle Cable (Accelerator)E. Throttle Cable (Decelerator)F. Holder ScrewFront Brake M

10 ASSEMBLYClutch Master Cylinder•Apply s ilicone grease or PBC grease to themaster cylinder clamp bolts.•Install the clutch master cylinder with itsc

ASSEMBLY11A. Left Switch LeadB. Clutch HoseC. Fasten the left switch lead and the clutch hose with two plastic clamps.D. Fasten the right switch lead

12 ASSEMBLYFront Fender Installation•Lift the motorcycle off the crate base and sup-port the motorcycle with a suitable stand orjack.•Loosen the axle

ASSEMBLY13A. Front TireB. ArrowC. Rotation•Fit the axle collars on both sides of the frontwheel hub. The collars are identical.•Put the front wheel as

14 ASSEMBLY•Check the front brake.A. Front Brake Caliper (Left)B. Bolts (D = 10, L = 47)WARNINGDo not attempt to ride the motorcycle un-til a full bra

ASSEMBLY15Front Footboard (Left)NOTEżInstall the left footboard after the “Clutch Fluid”section in the Preparation chapter.•Install the left footboard

16 ASSEMBLYHelmet Locks•Unlock the helmet lock with the key and fitthe small projection of the lock into the holein the bracket of each rear guard and

ASSEMBLY17Label Installation (for US and CN Mod-els only)•Wipe off any oil or grease from the applicationarea.•Peel the warning label off the backing

ForewordIn order to ship Kawasaki vehicles as effi-ciently as possible, they are partially disassem-bled before crating. Since some of the mostcommonl

18 ASSEMBLYA. HornB. Bolt (D = 8, L = 12)C. BracketChoke Knob•Loosen the locknut and fasten the choke knobto the bracket with locknut.A. Choke KnobB.

ASSEMBLY19A. Lower Hexagonal Area for TighteningB. Upper Hexagonal Area (Adapter)C. StayD. Non-permanent Locking Agent applied.•Turn the stay to assur

20 ASSEMBLYA. Windshield AssemblyB. Socket Bolts (D = 8, L = 10)Trim Installation [EUR Models Only]•Fit the windshield trim onto the edge of thewindsh

ASSEMBLY21A. BoltsB. Sub-windshieldLicense Plate BracketLicense Plate Bracket Installation•Install the license plate bracket onto the rearfender with

22 ASSEMBLYA. ReflectorB. License Plate HolderC. Cap Nut (D = 5)•Install the license plate holder on the licenseplate bracket with the bolts (D = 6, L

ASSEMBLY23A. LockB. Left SaddlebagC. Locked-position MarkD. ProjectionsE. NotchesNOTEżPush the lid lock all the way into the hole inthe lid so that th

24 PREPARATION•Measure the clearances between both thefront and rear upper dampers and the up-per mounting bracket with the saddlebaglightly pushed by

PREPARATION 25BatteryModelNameforVN1600–D1: FTZ16–BSA. Model Name of the ElectrolyteB. Model Name of the BatteryCAUTIONSealed battery electrolyte has

26 PREPARATIONA. Wiring ClampB. 1P Connector (Negative Lead)C. 2 P ConnectorD. 3 P ConnectorE. Battery Holder NutsF. Battery HolderG. BatteryH. 6 P Co

PREPARATION 27•Place the electrolyte container upside downwith the six sealed cells into the filler portsof the battery. Hold the container level, pus

Table of ContentsUncrating ...3Opening Crate ...

28 PREPARATIONCAUTIONOnce the strip of caps [A] is installedonto the battery, never remove the caps,nor add water or electrolyte to the bat-tery.NOTEż

PREPARATION 29Viewed from RightA. Positive Terminal (+)B. BatteryC. Positive Cable (+)D. ECU RelayE. Negative Cable (–)Viewed from TopA. Negative Cabl

30 PREPARATIONA. Bolt (D = 6, L = 14)B. Passenger’s SeatFront Brake FluidFront Brake Fluid Level Inspection•With the front brake fluid reservoir held

PREPARATION 31•Attach a clear plastic hose to the bleed valveon each front brake caliper and run the otherend of the hose into a container.•With the r

32 PREPARATION•Operate the brake lever several times.•If it feels spongy, there might be air in thebrake line.•If necessary, bleed the air in the rear

PREPARATION 33A. Clutch Fluid ReservoirB. Upper Level Line•Operate the clutch lever several times.•If it feels spongy, there might be air in the line.

34 PREPARATIONRear Shock AbsorberAir Pressure AdjustmentSTD Air pressure: AtmosphericRebound Damping Force Adjustment•Check the position of the reboun

PREPARATION 35A. F (Full) MarkB. L (Low) MarkC. Right Side CoverCoolant Filling•If the amount of coolant is insufficient, removethe right side cover,

36 PREPARATIONA. Oil Filler CapB. Oil Level Sight GaugeC. H (High) Level LineD. L (Low) Level Line•If the oil level is too high, remove the excessoil

PREPARATION 37•When replacing the filler cap, be sure the O-ring is in place, and install the cap.Final Gear Case OilType:API “GL-5”Hypoid gear oilVis

38 PREPARATIONHeadlight AimThe headlight beam is adjustable both hori-zontally and vertically. Headlight aim must becorrectly adjusted for safe riding

PREPARATION 39A. Rear Brake Light SwitchB. Adjusting NutC. Lights sooner.D. Lights later.CAUTIONTo avoid damaging the electrical con-nections inside t

40 PREPARATIONFastener Check•The torque values listed are for assembly andpreparation items only, see the appropriateService Manual for a more compreh

PREPARATION 41TorqueNo. FastenerN·m kgf·m ft·lbRemarksSteering1 Handlebar clamp bolts 34 3.5 252 Steering stem head nut 88 9.0 65Brake3 Front master c

42 PREPARATIONStandard Torque TableThis table relating tightening torque to threaddiameter, lists the basic torque for bolts andnuts. Use this table f

MODEL APPLICATIONYear Model Name2005 VN1600–D1VULCAN 1600 NOMADVN1600 CLASSIC TOURERPart No. 99931-1445 -01

UNCRATING 3UncratingOpening Crate•Clear a space about 6 m (20 ft.) square togive yourself plenty of space to work.•Place the crate upright on its base

4 UNCRATINGParts Check•Open the parts box, and check the parts against the illustrations. There may be minor differencesbetween these illustrations an

UNCRATING 5No. Part NameQtyRemarks1Handlebar with Grip1Handlebar Clamp2Clamp Bolt, Socket4 D = 10, L = 23Plastic Plug, Clamp Bolt4 LargeThrottle Grip1

6 UNCRATING* : European Models Only

UNCRATING 7No. Part NameQtyRemarks8 Horn with Bracket 1Flanged Bolt, Horn 19 License Plate Bracket1Bolt, B racket, License Plate 2 D=6,L=12Bracket, Re