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VULCAN 1600 MEAN STREAK

VN1600 MEAN STREAK

Motorcycle

Service Manual

Quick Reference Guide

VULCAN 1600 MEAN STREAK

VN1600 MEAN STREAK

All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts.

LIST OF ABBREVIATIONS

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.

1. Crankcase Emission Control System

This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the fuel injection system.

2. Exhaust Emission Control System

This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels.

The exhaust system of this model motorcycle manufactured primarily for sale in California includes a catalytic converter system.

3. Evaporative Emission Control System

Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead, fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as the Act’s «tampering provisions.»

«Sec. 203(a) The following acts and the causing thereof are prohibited…

(3)(A) for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser.

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor vehicles or motor vehicle engines, or who operates a fleet of motor vehicles knowingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title following its sale and delivery to the ultimate purchaser…»

NOTE

○The phrase «remove or render inoperative any device or element of design» has been generally interpreted as follows:

1. Tampering does not include the temporary removal or rendering inoperative of devices or elements of design in order to perform maintenance.

2. Tampering could include:

a.Maladjustment of vehicle components such that the emission standards are exceeded.

b.Use of replacement parts or accessories which adversely affect the performance or durability of the motorcycle.

c.Addition of components or accessories that result in the vehicle exceeding the standards.

d.Permanently removing, disconnecting, or rendering inoperative any component or element of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

•Among those acts presumed to constitute tampering are the acts listed below:

Replacement of the original exhaust system or muffler with a component not in compliance

•with Federal regulations.

•Removal of the muffler(s) or any internal portion of the muffler(s).

•Removal of the air box or air box cover.

Modifications to the muffler(s) or air inlet system by cutting, drilling, or other means if such modifications result in increased noise levels.

Foreword

GENERAL INFORMATION 1-1

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts.

Especially note the following:

Battery Ground

Before completing any service on the motorcycle, disconnect the battery wires from the battery to prevent the engine from accidentally turning over. Disconnect the ground wire (-) first and then the positive (+). When completed with the service, first connect the positive (+) wire to the positive (+) terminal of the battery then the negative (-) wire to the negative terminal.

Edges of Parts

Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts.

Solvent

Use a high flush point solvent when cleaning parts. High flush point solvent should be used according to directions of the solvent manufacturer.

Cleaning vehicle before disassembly

Clean the vehicle thoroughly before disassembly. Dirt or other foreign materials entering into sealed areas during vehicle disassembly can cause excessive wear and decrease performance of the vehicle.

GENERAL INFORMATION 1-3

Before Servicing

Arrangement and Cleaning of Removed Parts

Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly.

Storage of Removed Parts

After all the parts including subassembly parts have been cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly.

Inspection

Reuse of worn or damaged parts may lead to serious accident. Visually inspect removed parts for corrosion, discoloration, or other damage. Refer to the appropriate sections of this manual for service limits on individual parts. Replace the parts if any damage has been found or if the part is beyond its service limit.

Replacement Parts

Replacement Parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, Oil seals, Grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.

Assembly Order

In most cases assembly order is the reverse of disassembly, however, if assembly order is provided in this Service Manual, follow the procedures given.

1-4 GENERAL INFORMATION

Before Servicing

Tightening Sequence

Bolts, nuts, or screws must be tightened according to the specified sequence to prevent case warpage or deformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequence is followed twice-initial tightening and final tightening with torque wrench.

Force

Use common sense during disassembly and assembly, excessive force can cause expensive or hard to repair damage. When necessary, remove screws that have a non -permanent locking agent applied using an impact driver. Use a plastic-faced mallet whenever tapping is necessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-rings after disassembly can reduce sealing performance. Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling

Liquid Gasket, Locking Agent

For applications that require Liquid Gasket or a Locking Agent, clean the surfaces so that no oil residue remains before applying liquid gasket or locking agent. Do not apply them excessively. Excessive application can clog oil passages and cause serious damage.

GENERAL INFORMATION 1-5

Before Servicing

Press

For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the contact area. Be sure to maintain proper alignment and use smooth movements when installing.

Ball Bearing and Needle Bearing

Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting pressure on the correct bearing race as shown.

Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage.

Oil Seal, Grease Seal

Do not remove pressed oil or grease seals unless removal is necessary. Replace with new ones whenever removed. Press new oil seals with manufacture and size marks facing out. Make sure the seal is aligned properly when installing.

Circlips, Cotter Pins

Replace circlips or cotter pins that were removed with new ones. Install the circlip with its sharp edge facing outward and its chamfered side facing inward to prevent the clip from being pushed out of its groove when loaded. Take care not to open the clip excessively when installing to prevent deformation.

Lubrication

It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubrication points are called out throughout this manual, apply the specific oil or grease as specified.

1-6 GENERAL INFORMATION

Before Servicing

Direction of Engine Rotation

When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Rotate the crankshaft to positive direction (clockwise viewed from output side).

Electrical Wires

A two-color wire is identified first by the primary color and then the stripe color. Unless instructed otherwise, electrical wires must be connected to those of the same color.

GENERAL INFORMATION 1-7

Model Identification

VN1600-B1 (US, and Canada) Left Side View:

VN1600-B1 (US, and Canada) Right Side View:

1-8 GENERAL INFORMATION

Model Identification

VN1600-B1 (Europe) Left Side View:

VN1600-B1 (Europe) Right Side View:

1-10 GENERAL INFORMATION

General Specifications

1-12 GENERAL INFORMATION

Unit Conversion Table

Units of Temperature:

* ODOMETER READING km × 1000 (mile × 1000)

2-2 PERIODIC MAINTENANCE

Periodic Maintenance Chart

The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected.

FREQUENCY Whichever comes

first

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

2-4 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

2-10 PERIODIC MAINTENANCE

Specifications

PERIODIC MAINTENANCE 2-11

Specifications

2-12 PERIODIC MAINTENANCE

Special Tools

PERIODIC MAINTENANCE 2-13

Periodic Maintenance Procedures

Fuel System (DFI)

Fuel Hose and Connection Inspection

○The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the high pressure inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank (see Fuel System chapter) and check the fuel hose.

Replace the fuel hose if any fraying, cracks [B] or bulges

•[C] are noticed.

Check that the hoses are securely connected and clamps

•are tightened correctly.

When installing, route the hoses according to Cable,

•Wire, and Hose Routing section in the Appendix chapter. When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed.

Replace the hose if it has been sharply bent or kinked.

•Check that the throttle grip moves smoothly from close to full open, and the throttle closes quickly and completely in all steering positions by the return spring.

If the throttle grip doesn’t return properly, check the throttle cable routing, grip free play, and cable damage. Then

•lubricate the throttle cable.

Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed doesn’t change.

If the idle speed increases, check the throttle grip free play and the cable routing.

•If necessary, adjust the throttle cable as follows: ○Loosen the locknuts [A] and screw the adjusters [B] all the

way in so as to give the throttle grip plenty of play (rear view).

○Turn out the adjuster of the decelerator cable [C] until there is no play.

○Tighten the locknut against the adjuster.

○Turn the adjuster of the accelerator cable [D] until the proper amount of throttle grip free play is obtained and tighten the locknut against the adjuster.

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Idle• Speed Inspection

Start the engine and warm it up thoroughly.

○At first the engine will run fast to decrease warm up time (fast idle).

○Gradually the fast idle will lower to a certain RPM auto-

•matically. This is the idle speed. Check the idle speed.

Idle Speed

• Standard: 950 ±50 r/min (rpm)

With the engine idling, turn the handlebar to both sides. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed or damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing section in the Appendix chapter).

WARNING

Operation with improperly adjusted, incorrectly routed or damaged cables could result in an unsafe riding condition.

•If the idle speed is out of the specified range, adjust it. Start the engine and warm it up thoroughly.

○•Wait until fast idle speed lowers to a certain value.

Turn the adjusting screw [A] until the idle speed is correct. ○Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if

necessary. Front [B]

Air Cleaner Element Cleaning

NOTE

○In dusty areas, the element should be cleaned more frequently than the recommended interval.

○After riding through rain or on muddy roads, the element should be cleaned immediately.

•Remove:

Allen Bolt [A] and Washer and Left Air Cleaner Cover [B]

Front [C]

•Remove the element [A].

•Push a clean, lint-free towel into the lower air cleaner duct to keep dirt or other foreign material from entering.

WARNING

If dirt or dust is allowed to pass through into the throttle body assy, the throttle may become stuck, possibly causing accident.

CAUTION

If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

PERIODIC MAINTENANCE 2-15

Periodic Maintenance Procedures

•Clean the element by tapping it lightly to loosen dust.

•Blow away the remaining dust by applying compressed air [A] from the inside to the outside (from the clean side

•to the dirty side).

Visually check the element for no tears or no breaks and check the sponge gasket [B] also.

If the element or gasket has any tears or breaks, replace

•the element.

Install the left air cleaner cover.

Torque — Left Air Cleaner Cover Allen Bolt: 16 N·m (1.6 kgf·m, 12 ft·lb)

Evaporative Emission Control System Inspection (CAL)•

Inspect the canister as follows:

○Remove the left side cover (see Frame chapter). ○Remove the band [A] and take out the canister [B]. ○Visually inspect the canister for cracks and other damage.

If the canister has any cracks or bad damage, replace it with a new one.

NOTE

○The canister is designed to work well through the motorcycle’s life without any maintenance if it is used under normal conditions.

○Run the purge hose (green) [A] above the canister breather hose (blue) [B] through the hole [C] into the tool case [D].

○Do not run these hoses side by side on the battery side of the canister. This prevents hoses from being flattened when installing the left side cover.

○Install the canister and the left side cover (see Frame chapter).

○Face the white mark [E] left as shown.

•Check the liquid/vapor separator as follows: ○Disconnect the hoses from the separator, and remove the

separator [A] from the motorcycle right side. Front [B]

○Visually inspect the separator for cracks and other damage.

If the separator has any cracks or damage, replace it with a new one.

○To prevent the gasoline from flowing into or out of the

•canister, hold the separator perpendicular to the ground. Check the hoses of the evaporative emission control system as follows:

○Check that the hoses are securely connected and clips are in position.

○Replace any kinked, deteriorated or damaged hoses. ○Route the hoses according to Cable, Wire, and Hose

Routing section in the Appendix chapter. Refer to the diagram of the evaporative emission control system in the Fuel System chapter too.

○When installing the hoses, avoid sharp bending, kinking, flattening or twisting, and route the hoses with a minimum of bending so that the emission flow will not be obstructed.

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Cooling System

Radiator Hose and Connection Inspection

○The high pressure inside the radiator hose can cause coolant to leak [A] or the hose to burst if the line is not properly maintained. Visually inspect the hoses for signs of deterioration. Squeeze the hoses. A hose should not be hard and brittle, nor should it be soft or swollen.

Replace the hose if any fraying, cracks [B] or bulges [C]

•are noticed.

Check that the hoses are securely connected and clamps are tightened correctly.

Torque — Radiator Hose Clamp Screws: 2.5 N·m (0.25 kgf·m, 22 in·lb)

Coolant Change

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down.

Coolant on tires will make them slippery, and can cause an accident and injury.

Since coolant is harmful to the human body, do not use for drinking.

•Place a container under the radiator drain bolt [A], then remove the drain bolt (front view).

•Remove the fuel tank (see Fuel System (DFI) chapter).

•Remove the radiator cap [A] in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap.

○The coolant will drain from the radiator and engine. Front [B]

•Remove the water pump drain bolt [A]. The remaining coolant will drain from the water pump [B].

○Place a conduit under the drain hole of the pump cover. The conduit leads to a container.

Front [C]

PERIODIC MAINTENANCE 2-17

Periodic Maintenance Procedures

•Remove :

Right Side Cover (see Frame chapter)

• Reserve Tank Bolts

Turn over the reserve tank [A], remove the cap [B], and

•pour the coolant into a suitable container.

•Install the reserve tank.

When filling the coolant, choose a suitable mixture ratio by referring to the coolant manufacturer’s directions.

CAUTION

Soft or distilled water must be used with the antifreeze (see Specifications in this chapter) in the cooling system.

If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system.

•Tighten the drain bolts.

Torque — Radiator Drain Bolt: 2.2 N·m (0.22 kgf·m, 19 in·lb)

• Water Pump Drain Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)

Fill the coolant into the radiator.

NOTE

○Fill in the coolant slowly so that it can expel the air from the engine and radiator.

•Check the cooling system for leaks.

•Bleed the air from the water pump [A].

○Loosen the air bleeder bolt [B] until the coolant seeps out around the bolt, then tighten it.

Torque — Water Pump Air Bleeder Bolt: 11 N·m (1.1 kgf·m, 97 in·lb)

•Next, loosen the air bleeder bolt [A] on the thermostat housing.

• Front [B]

Replenish the coolant into the radiator until the coolant begins to flow out the air bleeder bolt hole (that is, all the

•remaining air is forced out).

Tap the radiator hoses to force any air bubbles caught inside.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Fill the radiator up to the filler neck [A] with coolant.

•Install the radiator cap.

•Tighten the air bleeder bolt [B].

Torque — Thermostat Air Bleeder Bolt: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•Fill the reserve tank up to the “F” (full) level line [A] with

•coolant and install the cap.

•Install the fuel tank (see Fuel System (DFI) chapter). Start the engine and warm it up thoroughly until the radi-

•ator fan turns on and then stop the engine.

Check the coolant level in the reserve tank several times while the engine is cooling down, and replenish as necessary.

If the coolant level is lower than the “L” level line, add coolant to the “F” level line.

CAUTION

Do not add more coolant above the “F” level line.

Engine Top End

Air• Suction Valve Inspection

Remove the air suction valve (see Engine Top End chap-

•ter).

Visually inspect the reeds for cracks, folds, warps, heat damage or other damage.

If there is any doubt as to the condition of the reeds [A],

•replace the air suction valve as an assembly.

Check the reed contact areas [B] of the valve holder for grooves, scratches, any signs of separation from the holder or heat damage.

•If there is any doubt as to the condition of the reed contact

•areas, replace the air suction valve as an assembly.

If any carbon or other foreign particles have accumulated between the reed and the reed contact area, wash the valve assembly clean with a high-flash point solvent.

CAUTION

Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assembly.

PERIODIC MAINTENANCE 2-19

Periodic Maintenance Procedures

Clutch

Clutch• Hose and Connection Inspection

The high pressure inside the clutch line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained. Bend and twist the rubber hose while examining it.

Replace it if any fraying, cracks [B] or bulges [C] are no-

•ticed.

Check that the hoses are securely connected and banjo bolts are tightened correctly.

Torque — Clutch Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

• ft·lb)

When installing the clutch hose, route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.

Replace the hose if it has been sharply bent or kinked.

Clutch• Fluid Level Inspection

•Hold the clutch fluid reservoir horizontal.

Check that the clutch fluid level of the clutch reservoir is between the lower [A] and the upper [B] level lines.

If the fluid level is lower than the lower level line, fill the reservoir to the upper level line in the reservoir.

○Since the clutch fluid is the same as the brake fluid, refer to Brakes Section in the this chapter for further details.

Torque — Clutch Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)

WARNING

Change the fluid in the clutch line completely if the fluid must be refilled but the type and brand of the fluid that already is in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter. Mixing different types and brands of fluid lowers the fluid boiling point and could cause the clutch to be ineffective. It may also cause the rubber clutch parts to deteriorate.

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Clutch• Fluid Change

Level the clutch fluid reservoir and remove the reservoir

•cap.

Remove the alternator outer cover (see Electrical System chapter.) and the rubber cap from the bleed valve on the

•clutch slave cylinder.

Attach a clear plastic hose [A] to the bleed valve and run

•the other end of the hose into a container.

•Fill the reservoir with fresh fluid. Change the clutch fluid as follows.

Open [B] the bleed valve, using a wrench.

Pump the clutch lever and hold [C] it.

Close [D] the bleed valve.

Release [E] the clutch lever.

○Repeat this operation until fresh fluid comes out from the plastic hose or the color of the fluid changes.

○Check the fluid level in the reservoir often, replenishing it as necessary.

NOTE

○If the fluid in the reservoir runs completely out any time during fluid changing, the bleeding operation must be done over again from the beginning since air will have entered the line.

WARNING

Do not mix two brands of fluid.

•After changing the fluid, check the clutch for good clutch power and no fluid leakage.

If necessary, bleed the air from the lines (see Clutch Line

•Bleeding in the Clutch chapter).

•Remove the clear plastic hose.

•Install the reservoir cap.

Tighten the bleed valve, and install the rubber cap.

Torque — Clutch Reservoir Cap Screws: 1.5 N·m (0.15 kgf·m, 13 in·lb)

Clutch Slave Cylinder Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)

PERIODIC MAINTENANCE 2-21

Periodic Maintenance Procedures

Clutch Master Cylinder Cup and Dust Seal

Replacement•

•Remove the clutch master cylinder (see Clutch chapter). Remove the reservoir cap [A] and diaphragm [B], and

•pour the clutch fluid into a container.

Unscrew the locknut [C] and pivot bolt [D], and remove

•the clutch lever [E].