Kawasaki Vulcan 1600 Series Motorcycle (2003-2008) Service Repair Manual

The online edition of this manual will be available immediately without download. The physical manual will be dispatched directly by Haynes and will arrive separately from any other parts ordered.

Kawasaki Vulcan 1600 Series Service and Repair Manual (2003-2008) M245This manual covers all models of Kawasaki Vulcan 1600 Series motorcycles including: Classic, Mean Streak and Nomad Manual. Includes Color Wiring Diagrams. This service manual provides specific, detailed instructions for performing everything from basic maintenance and troubleshooting to a complete overhaul of all models of the Kawasaki Vulcan 1600 Series motorcycle. Do-it-yourselfers will find this service and repair manual more comprehensive than the factory manual, making it an indispensable part of your tool box.

Every Clymer manual contains hundreds of original photographs and illustrations developed from a complete disassembly and assembly of a motorcycle. This, in addition to extensive research, allows Clymer to achieve an unmatched level of detail, accuracy and clarity.The step-by-step instructions and two-column text with large print are user-friendly. Bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb-tabbed chapters, numbered table of contents and an extensive index make it possible to locate the desired section quickly.

The Haynes Online Manual gives you the trusted content of the famous printed Workshop Manual with extra features to get the job done. Online Manuals provide the following benefits: Troubleshooting tool for fast diagnosis of common problems. Colour-coded wiring diagrams for key systems. Videos tutorials for common DIY tasks. Colour photographs with approximately 750 in each manual. Photos can be zoomed in to observe key details. Fully searchable Dictionary of automotive terms. Hyperlinks to additional relevant information in other manual chapters. Print any page at home.

Kawasaki Vulcan 1600 Series Classic, Mean Streak and Nomad Manual. Includes Color Wiring Diagrams.

What's Covered

THIS KAWASAKI VULCAN 1600 MANUAL IS 480 PAGES.

• QUICK REFERENCE DATA
• CHAPTER ONE / GENERAL INFORMATIONMANUAL ORGANIZATION / WARNINGS, CAUTIONS AND NOTES / SAFETY / SERIAL NUMBERS AND INFORMATION LABELS / FASTENERS / SHOP SUPPLIES / TOOLS / MEASURING TOOLS / ELECTRICAL SYSTEM FUNDAMENTALS / SERVICE METHODS / STORAGE / SPECIFICATIONS
• CHAPTER TWO / TROUBLESHOOTINGSTARTING 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 THREE / LUBRICATION, MAINTENANCE AND TUNE-UPMAINTENANCE 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 FOUR / ENGINE TOP ENDROCKER 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 FIVE / ENGINE LOWER ENDSERVICING 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 SIX / CLUTCHCLUTCH BLEEDING / CLUTCH FLUID DRAINING AND FLUSHING / CLUTCH MASTER CYLINDER / CLUTCH SLAVE CYLINDER / CLUTCH COVER / CLUTCH / INNER HUB / SPECIFICATIONS
• CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISMTRANSMISSION / INTERNAL GEARSHIFT MECHANISM / SPECIFICATIONS
• CHAPTER EIGHT / FUEL SYSTEMDIGITAL 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 NINE / ELECTRICAL SYSTEMELECTRICAL 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 TEN / COOLING SYSTEMCOOLING SYSTEM INSPECTION / RADIATOR / RADIATOR FAN / COOLANT RESERVE TANK / THERMOSTAT / WATER PUMP / SPECIFICATIONS
• CHAPTER ELEVEN / WHEEL AND TIRESMOTORCYCLE LIFT / FRONT WHEEL / REAR WHEEL / FRONT AND REAR HUBS / REAR WHEEL COUPLING / WHEEL SERVICE / TIRE SERVICE / WHEEL BALANCE / SPECIFICATIONS
• CHAPTER TWELVE / FRONT SUSPENSION AND STEERINGHANDLEBAR / HANDLEBAR GRIPS / STEERING ASSEMBLY / STEERING ADJUSTMENT / STEERING HEAD BEARING RACE / STEERING STEM BEARING / FRONT FORK / SPECIFICATIONS
• CHAPTER THIRTEEN / REAR SUSPENSION AND FINAL DRIVESHOCK ABSORBER / FINAL DRIVE UNIT / SWING ARM AND DRIVE SHAFT / SPECIFICATIONS
• CHAPTER FOURTEEN / BRAKESBRAKE 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 FIFTEEN / BODY AND EXHAUST SYSTEMREAR 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
• MODELS COVERED: VULCAN CLASSIC A1 A2 A3 2003 2004 2005VULCAN CLASSIC A6F AND E6F 2006VULCAN CLASSIC A7F AND A7FA 2007VULCAN CLASSIC A8F AND A8FA 2008VULCAN MEAN STREAK B1 - B2 2004 2005VULCAN MEAN STREAK B6F AND F6F 2006VULCAN MEAN STREAK B7F AND B7FA 2007VULCAN MEAN STREAK B8F AND B8FA 2008VULCAN NOMAD D1 2005VULCAN NOMAD D6F AND G6F 2006VULCAN NOMAD D7F AND D7FA 2007VULCAN NOMAD D8F AND D8FA 2008VN1600VN 1600
• CLYMER MANUALS VULCAN CLASSIC A1 MANUALCLYMER MANUALS VULCAN CLASSIC A2 MANUALCLYMER MANUALS VULCAN CLASSIC A3 MANUALCLYMER MANUALS VULCAN CLASSIC A6F MANUALCLYMER MANUALS VULCAN CLASSIC E6F MANUALCLYMER MANUALS VULCAN CLASSIC A7F MANUALCLYMER MANUALS VULCAN CLASSIC A7FA MANUALCLYMER MANUALS VULCAN CLASSIC A8F MANUALCLYMER MANUALS VULCAN CLASSIC A8FA MANUALCLYMER MANUALS VULCAN MEAN STREAK B MANUALCLYMER MANUALS VULCAN MEAN STREAK B2 MANUALCLYMER MANUALS VULCAN MEAN STREAK B6F MANUALCLYMER MANUALS VULCAN MEAN STREAK F6F MANUALCLYMER MANUALS VULCAN MEAN STREAK B7F MANUALCLYMER MANUALS VULCAN MEAN STREAK B7FA MANUALCLYMER MANUALS VULCAN MEAN STREAK B8F MANUALCLYMER MANUALS VULCAN MEAN STREAK B8FA MANUALCLYMER MANUALS VULCAN NOMAD D1 MANUALCLYMER MANUALS VULCAN NOMAD D6F MANUALCLYMER MANUALS VULCAN NOMAD G6F MANUALCLYMER MANUALS VULCAN NOMAD D7F MANUALCLYMER MANUALS VULCAN NOMAD D7FA MANUALCLYMER MANUALS VULCAN NOMAD D8F MANUALCLYMER MANUALS VULCAN NOMAD D8FA MANUALCLYMER MANUALS VULCAN CLASSIC MANUALCLYMER MANUALS VULCAN MEAN STREAK MANUALCLYMER MANUALS VULCAN NOMAD MANUAL