Page 2 - Foreword; WARNING; NOTE
Foreword In order to ship Kawasaki vehicles as effi- ciently as possible, they are partially disassem-bled before crating. Since some of the mostcommonly removed parts have a direct bear-ing on a vehicle’s reliability and safety, consci-entious pre-sale assembly and preparation be-comes extremely im...
Page 3 - Table of Contents; Uncrating
Table of Contents Uncrating ...................................................................................... 3 Opening Crate ............................................................................. 3 Parts Check ................................................................................
Page 5 - UNCRATING 3; Opening Crate; CAUTION; This could damage the fuel
UNCRATING 3 Uncrating Opening Crate • Clear a space about 6 m (20 ft.) square togive yourself plenty of space to work. • Place the crate upright on its base. • Remove the cardboard cover. • Remove the handlebar, front wheel, and theparts box. CAUTION When you remove the crate bracketfrom the motorcy...
Page 6 - UNCRATING; Parts Check
4 UNCRATING Parts Check • Open the parts box, and check the parts against the illustrations. There may be minor differencesbetween these illustrations and the actual vehicle parts. In the following charts under Remarks, D= diameter in millimeters, L = length in millimeters, and T = Thickness in mill...
Page 8 - UNCRATING
Page 9 - UNCRATING 7
UNCRATING 7 No. Part Name Qty Remarks 8 Horn with Bracket 1 Flanged Bolt, Horn 1 9 License Plate Bracket 1 Bolt, Bracket, License Plate 2 D = 6, L = 12 Bracket, Reflector 1 (US)(CN)(AUS) only Reflector 3 (US)(CN) only Reflector 1 (AUS) only Cap Nut, Reflector 3 D = 5, (US)(CN) only Cap Nut, Reflecto...
Page 10 - ASSEMBLY; Assembly; Handlebar; Handlebar Clamp Bolt Tightening; Throttle Grip and Right Switch; Alignment Pin Type
8 ASSEMBLY Assembly Handlebar NOTE ż Position the handlebar clamp on the handle-bar with the slanted side facing rearward. • Set the handlebar to match its punched markto the rear portion of the lower clamp matingface and install the upper clamps and bolts (D= 10, L = 23). A. Front BoltsB. Slanted S...
Page 11 - ASSEMBLY 9; Front Brake Master Cylinder
ASSEMBLY 9 A. Right Switch HousingB. Screws (L = 25)C. HarnessD. Throttle Cable (Accelerator)E. Throttle Cable (Decelerator)F. Holder Screw Front Brake Master Cylinder • Connect the right switch housing lead con-nectors to the front brake light switch termi-nals on the front brake master cylinder. •...
Page 13 - Front Fender; Front Reflectors (for US and CN Models
ASSEMBLY 11 A. Left Switch LeadB. Clutch HoseC. Fasten the left switch lead and the clutch hose with two plastic clamps.D. Fasten the right switch lead with the plastic clamp.E. Fasten the right switch lead and the brake hose with the plastic clamp.F. Throttle CablesG. Brake HoseH. Right Switch Lead...
Page 14 - Front Fender Installation; After removing the; US and CN Models; Front Wheel Installation
12 ASSEMBLY Front Fender Installation • Lift the motorcycle off the crate base and sup-port the motorcycle with a suitable stand orjack. • Loosen the axle clamp bolts on the right forkleg and remove the front axle. • Loosen the two flanged bolts (D = 10, L = 47)to remove each front brake caliper. A....
Page 16 - Front Brake Hose Grommets; Front and Rear Shift Pedals
14 ASSEMBLY • Check the front brake. A. Front Brake Caliper (Left)B. Bolts (D = 10, L = 47) WARNING Do not attempt to ride the motorcycle un-til a full brake lever is obtained by pump-ing the brake lever until the pads areagainst the disc. The brake will not func-tion on the first application of the...
Page 17 - Front Guards Installation
ASSEMBLY 15 Front Footboard (Left) NOTE ż Install the left footboard after the “Clutch Fluid”section in the Preparation chapter. • Install the left footboard assembly on theframe with one bolt (D = 10, L = 30) at therear and tighten it. A. Front Footboard (Left)B. Bolt (Rear) NOTE ż The bolt in fron...
Page 18 - Helmet Locks; Rear Guards Installation
16 ASSEMBLY Helmet 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 fastenit with the screw (D = 5, L = 12) having anon-permanent locking agent. • Lock the helmet lock. A. Helmet LockB. Ignition KeyC. ProjectionD. ...
Page 19 - Backrest Pad; Horn
ASSEMBLY 17 Label Installation (for US and CN Mod- els only) • Wipe off any oil or grease from the applicationarea. • Peel the warning label off the backing sheetand stick it on the rear left guard. A. Rear Guard (Left)B. Label For US Models (56070-1285)C. Label TopD. 20 mm (0.8 in.)E. Label For CN ...
Page 20 - Choke Knob; Turning Stay Type
18 ASSEMBLY A. HornB. Bolt (D = 8, L = 12)C. Bracket Choke Knob • Loosen the locknut and fasten the choke knobto the bracket with locknut. A. Choke KnobB. LocknutC. Bracket Rear View Mirrors (Left and Right) Conventional Type (Single Nut) • Loosen the locknut completely. • Screw the rear view mirror...
Page 21 - Windshield; A. Windshield Assembly
ASSEMBLY 19 A. Lower Hexagonal Area for TighteningB. Upper Hexagonal Area (Adapter)C. StayD. Non-permanent Locking Agent applied. • Turn the stay to assure visibility to the rearwith the operator sitting on the motorcycle. • Adjust the rear view mirror by slightly movingonly the mirror portion of th...
Page 22 - Windshield Height Adjustment; Sub-windshield Adjustment
20 ASSEMBLY A. Windshield AssemblyB. Socket Bolts (D = 8, L = 10) Trim Installation [EUR Models Only] • Fit the windshield trim onto the edge of thewindshield starting from each lower edge. • Fix the trim ends with the clamps (2). A. TrimB. Clamps Deflectors (Left and Right) Installation • Assemble ...
Page 23 - License Plate Bracket; License Plate Bracket Installation; Rear Reflectors and License Plate; US and CN Models only
ASSEMBLY 21 A. BoltsB. Sub-windshield License Plate Bracket License Plate Bracket Installation • Install the license plate bracket onto the rearfender with the bolts (D = 6, L = 12)(2). A. Rear FenderB. License Plate BracketC. Bolts (D = 6, L = 12) Rear Reflectors and License Plate Holder US and CN ...
Page 24 - only; Left Saddlebag; Left Saddlebag Lid Lock Installation
22 ASSEMBLY A. ReflectorB. License Plate HolderC. Cap Nut (D = 5) • Install the license plate holder on the licenseplate bracket with the bolts (D = 6, L = 14)(3)and plated cap nuts (3) and tighten them. Theremaining fasteners are used for the licenseplate. A. License Plate HolderB. Bolt (D = 6, L =...
Page 25 - Left Saddlebag Dampers Installation
ASSEMBLY 23 A. LockB. Left SaddlebagC. Locked-position MarkD. ProjectionsE. Notches NOTE ż Push the lid lock all the way into the hole inthe lid so that the projection ends are insertedinto it. A. Lock • Turn the key clockwise and counterclockwise,to check the saddlebag lid lock operation. Left Sadd...
Page 26 - 4 PREPARATION; Brake Disc Cleaning; Preparation; Battery Service
24 PREPARATION • Measure the clearances between both thefront and rear upper dampers and the up-per mounting bracket with the saddlebaglightly pushed by hand against the mountingbracket. • If the clearance is 1.0 mm (0.04 in.) or moreat the front and/or rear, adjust it. Insert one ortwo flat washer(...
Page 27 - PREPARATION 25; Battery Model Name for; Each; Riders Seat Removal
PREPARATION 25 Battery Model Name for VN1600–D1: FTZ16–BS A. Model Name of the ElectrolyteB. Model Name of the Battery CAUTION Sealed battery electrolyte has a higherconcentration of sulfuric acid. Each container contains the proper amountof electrolyte for its specific battery.Insufficient or incor...
Page 28 - 6 PREPARATION; Battery Specifications; Battery Activation; Filling the Battery with Electrolyte
26 PREPARATION A. Wiring ClampB. 1 P Connector (Negative Lead)C. 2 P ConnectorD. 3 P ConnectorE. Battery Holder NutsF. Battery HolderG. BatteryH. 6 P Connector (Rear Harness)I. 4 P Connector (Diagnosis)J. Plastic ClampK. 15 A Fuse HolderL. Harness (Fuel Pump)M. Harness (Fuel Gauge) • Remove the 15 A...
Page 29 - PREPARATION 27; Initial Charge; Standard Charge 1.8 A × 5
PREPARATION 27 • Place the electrolyte container upside downwith the six sealed cells into the filler portsof the battery. Hold the container level, pushdown to break the seals of all six cells. Youwill see air bubbles rising into each cell as theports fill. NOTE ż Do not tilt the electrolyte contai...
Page 30 - 8 PREPARATION; Battery Installation
28 PREPARATION CAUTION Once the strip of caps [A] is installedonto the battery, never remove the caps,nor add water or electrolyte to the bat-tery. NOTE ż To ensure maximum battery life and customersatisfaction, it is recommended the battery beload tested at three times its amp-hour ratingfor 15 sec...
Page 31 - PREPARATION 29; Viewed from Right; the Guide in the Battery Case.; Rider’s Seat Installation
PREPARATION 29 Viewed from Right A. Positive Terminal (+) B. Battery C. Positive Cable (+) D. ECU Relay E. Negative Cable (–) Viewed from Top A. Negative Cable (–) B. Run the Positive Cable (+) through the Guide in the Battery Case. C. Positive Cable (+) D. Battery E. 4 P Connector (Diagnosis) F. 6 ...
Page 32 - 0 PREPARATION; Front Brake Fluid; Front Brake Fluid Level Inspection; Front Brake Line Air Bleeding
30 PREPARATION A. Bolt (D = 6, L = 14)B. Passenger’s Seat Front Brake Fluid Front Brake Fluid Level Inspection • With the front brake fluid reservoir held hori-zontal, check that the fluid level is above thelower level line. A. Front Brake Fluid ReservoirB. Lower Level Line • If the fluid level in t...
Page 33 - PREPARATION 31; Rear Brake Fluid; Rear Brake Fluid Level Inspection
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 reservoir cap off, slowly pump thebrake lever several times until no air bubblescan be seen rising up through the fluid fromthe holes at the bottom...
Page 34 - 2 PREPARATION; Rear Brake Line Air Bleeding; Clutch Fluid; Clutch Fluid Level Inspection
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 brakeline. • Also check for fluid leakage around the fit-tings. Rear Brake Line Air Bleeding • Remove the rear brake reservoir cap and di-aphra...
Page 35 - PREPARATION 33; Clutch Line Air Bleeding
PREPARATION 33 A. Clutch Fluid ReservoirB. Upper Level Line • Operate the clutch lever several times. • If it feels spongy, there might be air in the line. • If necessary, bleed the air in the lines. • Also check for fluid leakage around the fit-tings. Clutch Line Air Bleeding • Loosen the mounting ...
Page 36 - 4 PREPARATION; Rear Shock Absorber; Air Pressure Adjustment; STD Air pressure: Atmospheric; Rebound Damping Force Adjustment; STD Rebound Damping Force:; Tire Air Pressures; A. Tire Air Pressure Gauge; Fuel; Coolant; Coolant Level Inspection
34 PREPARATION Rear Shock Absorber Air Pressure Adjustment STD Air pressure: Atmospheric Rebound Damping Force Adjustment • Check the position of the rebound dampingforce adjuster at the upper end of each rearshock absorber. It has four positions. Thenumbers on the adjuster show the setting po-sitio...
Page 37 - PREPARATION 35; Coolant Filling; Engine Oil Level Inspection
PREPARATION 35 A. F (Full) MarkB. L (Low) MarkC. Right Side Cover Coolant Filling • If the amount of coolant is insufficient, removethe right side cover, pull open the cap from thereserve tank and add coolant through the filleropening to the F (Full) mark. A. CapB. F (Full) MarkC. L (Low) Mark • Ins...
Page 38 - 6 PREPARATION; Recommended Engine Oil; Final Gear Case Oil; Final Gear Case Oil Level Inspection
36 PREPARATION A. 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 through the oil filler opening, using a sy-ringe or some other suitable device. • If the oil level is too low, add oil to reach thecorrect level. U...
Page 39 - PREPARATION 37; Throttle Grip and Cable; Throttle Grip Free Play Inspection; Throttle Grip Free Play:; Throttle Grip Free Play Adjustment
PREPARATION 37 • When replacing the filler cap, be sure the O-ring is in place, and install the cap. Final Gear Case Oil Type: API “GL-5”Hypoid gear oil Viscosity: SAE 90 [above 5°C (41°F)] SAE 80 [below 5°C (41°F)] Capacity: 0.2 L (0.21 US qt) Final Gear Case Oil Drain Plug Torque: 8.8 N·m (0.90 kg...
Page 40 - 8 PREPARATION; Headlight Aim; Horizontal Adjustment; Idle Speed Adjustment; A. Idle Adjusting Screw; Rear Brake Light Switch; Rear Brake Light Switch Adjustment
38 PREPARATION Headlight Aim The headlight beam is adjustable both hori- zontally and vertically. Headlight aim must becorrectly adjusted for safe riding as well as on-coming drivers. In most areas it is illegal to ridewith an improperly adjusted headlight. Horizontal Adjustment • Turn the horizonta...
Page 41 - PREPARATION 39
PREPARATION 39 A. Rear Brake Light SwitchB. Adjusting NutC. Lights sooner.D. Lights later. CAUTION To avoid damaging the electrical con-nections inside the switch, be sure thatthe switch body does not turn during ad-justment.
Page 42 - 0 PREPARATION; Fastener Check
40 PREPARATION Fastener Check • The torque values listed are for assembly andpreparation items only, see the appropriateService Manual for a more comprehensivelist. Check tightness of all fasteners that arein the table before retail delivery. Also checkto see that each cotter pin or circlip is in pl...
Page 44 - 2 PREPARATION; Standard Torque Table; Transmission
42 PREPARATION Standard Torque Table This table relating tightening torque to thread diameter, lists the basic torque for bolts andnuts. Use this table for only the bolts and nutswhich do not require a specific torque value.All of the values are for use with dry solvent-cleaned threads. General Fast...
Page 46 - MODEL APPLICATION
MODEL APPLICATION Year Model Name 2005 VN1600–D1 VULCAN 1600 NOMADVN1600 CLASSIC TOURER Part No. 99931-1445-01
