Kawasaki 1600 Motorcycle User Manual
Contents
1. ME02035B52 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 P Connector Rear Harness G Plastic Clamp H 15 A Fuse Holder I ECU Connector J 3 Connectors 1 P 2 P 3 P PREPARATION 29 Rider s Seat Installation e Insert the projection at the front of the rider s c lt A Projection B Receptacle e Install the bolt D 6 L 14 and tighten it A Rider s Seat B Bolt D 6 L 14 e Insert the projection at the front of the passen ger s seat into the receptacle on the frame A Receptacle B Projection e Install the bolt D 6 L 14 and tighten it 30 PREPARATION A Bolt D 6 L 14 B Passenger s Seat Front Brake Fluid Front Brake Fluid Level Inspection e With the front brake fluid reservoir held hori zontal check that the fluid level is above the lower level line A Front Brake Fluid Reservoir B Lower Level Line e f the fluid level in the reservoir is lower than the lower level line check for fluid leaks in the front brake lines and fill the reservoir e Loosen the screws to remove the front brake fluid reservoir cap and diaphragm e Fill the reservoir to the upper level line with DOT4 brake fluid Inside the front brake reservoir is a stepped line showing the upper level line2. A Front Brake Fluid Reservoir B Upper Level Line A WARNING Never reuse old brake fluid Do not use fluid from a container that has been left unsealed or that has been open for a long time Do not mix two types of fluid for use in the brakes This lowers the brake fluid boiling point and could reduce brake ef fectiveness It may also cause the rub ber brake parts to deteriorate Don t leave the reservoir cap off for any length of time to prevent moisture con tamination of the fluid Don t add or change brake fluid in the rain or during conditions of blowing dust or debris CAUTION Brake fluid quickly ruins painted sur faces Wipe up any spilled fluid immedi ately e Operate the brake lever several times elf it feels spongy there might be air in the brake line e f necessary bleed the air in the front brake lines e Also check for fluid leakage around the fit tings Front Brake Line Air Bleeding e Remove the reservoir cap and diaphragm and check that there is plenty of fluid in the reservoir NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be repeated from the beginning since air will have entered the line Attach a clear plastic hose to the bleed valve on each front brake caliper and run the other
3. MODEL APPLICATION Year Model Name 2005 VN1600 D1 VULCAN 1600 NOMAD VN1600 CLASSIC TOURER l 4 Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products Machinery Company Part No 99931 1445 01
4. A License Plate Holder B Bolt D 6 L 14 C Cap Nut D License Plate Bracket Left Saddlebag NOTE OInstall the saddlebags after the Final Gear Case Oil Rear Brake Fluid and Rear Shock Absorber sections in the Preparation chapter Left Saddlebag Lid Lock Installation NOTE OAfter the saddlebag is installed you can install the left saddlebag lid lock e Inspect the saddlebags for damage e Insert the ignition key into the lock and turn the key counterclockwise to the unlocked po sition hook faces left e With the locked position mark on the lock fac ing up toward the handle insert the hook of the lock then the lock into the hole in the left saddlebag lid and push it straight ahead so that the projections on the lock fit into the notches MD34000B51 C A Lock B Left Saddlebag C Locked position Mark D Projections E Notches NOTE OPush the lid lock all the way into the hole in the lid so that the projection ends are inserted into it MD34001B51 C A Lock e Turn the key clockwise and counterclockwise to check the saddlebag lid lock operation Left Saddlebag Dampers Installation e nsert the large dampers 2 so that the grooves fit into the holes in the lower brack ets of the left saddlebag muffler bracket M j4B002 P A Dampers ASSEMBLY 23 e Open the saddlebag lid and insert the upper dampers 2 into the holes
5. bly chapter 34 PREPARATION Rear Shock Absorber Air Pressure Adjustment STD Air pressure Atmospheric Rebound Damping Force Adjustment e Check the position of the rebound damping force adjuster at the upper end of each rear shock absorber It has four positions The numbers on the adjuster show the setting po sition STD Rebound Damping Force No 2 position A Air Valve B Rebound Damping Force Adjuster C Number e Turn the rebound damping force adjuster to the No 2 position Tire Air Pressures e To prevent flat spotting during shipment the tires are over inflated before crating Adjust the pressures to the specified values in the front and rear and make sure to tighten the caps securely Tire Air Pressure when cold Front 225 kPa 2 25 kgf cm 32 psi Rear 280 kPa 2 80 kgf cm 40 psi A Tire Air Pressure Gauge Fuel A WARNING Fill the tank in a well ventilated area and take ample care that there are no sparks or open flames anywhere near the work area e Open the fuel tank cap and check for debris in the fuel tank e Fill the fuel tank with one gallon or four liters of unleaded gasoline Use a gasoline with a minimum Antiknock Index rating according to the recommendation of your country Refer to the following table The antiknock index is an average of the Re search Octane Number RON and the Motor Octane Number MON as shown in the tabl
6. Front brake bleed valves Left and Right 6 Rear master cylinder mounting bolts 25 2 5 18 7 Rear caliper mounting bolts 34 3 5 25 8 Rear brake bleed valves 7 8 0 80 69 in lb Wheel 9 Front axle shaft 108 11 0 80 10 Front axle clamp bolts Right 29 3 0 21 AL Suspension Rear shock absorber mounting nuts Left and n Right Uper and Lower 7 21 ee e Others 12 Front footboard bracket bolts Left and Right 34 3 5 25 13 Rear footboard bracket bolts Left and Right 25 2 5 18 14 Clutch master cylinder clamp bolts 11 1 1 97 in lb Engine Engine Oil Drain Plugs 15 Engine oil drain plug 20 2 0 15 16 Final gear case drain plug 8 8 0 90 78 in lb Cotter Pin or Circlip 17 Rear axle nut cotter pin 18 Rear master cylinder cotter pin 19 Front footboard pin circlips Left and Right 20 Rear footboard pin circlips Left and Right AL Tighten the two clamp bolts alternately two times to ensure even tightening torque S Tighten the upper clamp bolt first and then the lower clamp bolt 42 PREPARATION Standard Torque Table This table relating tightening torque to thread diameter lists the basic torque for bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads General Fasteners Threads Torque dia mm N m kgf m ft lb 5 34 49 0 35 0 50 70 43 in Ib 6 59 7
7. Model Name of the Battery CAUTION concentration of sulfuric acid Each container contains the proper amount of electrolyte for its specific battery Insufficient or incorrect electrolyte will reduce battery performance and service life Electrolyte over capacity can lead to battery cracking or leaking and result in corrosion damage to the vehicle Riders Seat Removal e Remove the bolt D 6 L 14 and pull the A Bolt D 6 L 14 B Passenger s Seat e Remove the bolt D 6 L 14 and pull the rider s seat rearward Sealed battery electrolyte has a higher PREPARATION 25 A Rider s Seat B Bolt D 6 L 14 e Remove the screw D 6 L 14 and pull the right side cover outward to clear the pro jections A Right Side Cover B Screw D 6 L 14 C Projections e Unfasten the wiring clamp e Remove the two battery holder nuts and dis connect the white 1 P Pin 2 P and the 3 P connectors e Disconnect the 6 P connector and remove the black diagnosis 4 P connector from the holder and then unfasten the plastic clamp on the bottom of the battery holder while lift ing the holder 26 PREPARATION A Wiring Clamp B 1 P Connector Negative Lead C 2 P Connector D 3 P Connector E Battery Holder Nuts F Battery Holder G Battery H 6 P Connector Rear Harness Il 4 P Connector Diagnosis J Plastic Clamp K 15 A Fuse Holder L Harness Fuel
8. Nut Backrest Frame 2 2 1 2 2 2 1 1 1 2 2 2 2 2 4 4 2 2 1 1 1 1 4 4 4 D 8 L 30 D 10 L 50 Large D 8 L 35 D 8 Located in the left side cover D 5 L 12 US and CN Models Only 6 UNCRATING European Models Only UNCRATING 7 Part Name Remarks 8 Horn with Bracket Flanged Bolt Horn License Plate Bracket Bolt Bracket License Plate Bracket Reflector Reflector Reflector Cap Nut Reflector Cap Nut Reflector Cap Nut Black License Plate Cap Nut Black License Plate Flat Washer Black Holder License Plate Flat Washer Black Holder License Plate Holder License Plate Bolt with Flat Washer Bolt with Flat Washer Cap Nut Holder License Plate D 6 L 12 US CN AUS only US CN only AUS only D 5 US CN only D 5 AUS only 6 US only 6 CN AUS EUR only 6 5 x 20 x 1 6 US only 6 5 x 20 x 1 6 CN AUS EUR only UUOUU 4 US only 4 CN AUS EUR only Windshield Assembly with Center Plate Outer amp Inner Damper Center Plate Outer amp Inner Socket Bolt with Washer Center Plate Cap Nut Vulcan Mark VN1600 Mark Outer Plate LH amp RH Inner Plate LH amp RH Outer Damper Outer Plate LH amp RH Inner Damper Inner Plate LH amp RH Socket Bolt with Washer Outer amp Inner Plate Sub windshield Stay
9. end of the hose into a container e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir This bleeds the air from the brake master cylinder end of the line e Pump the brake lever a few times until it becomes hard and then holding the lever squeezed quickly open turn counterclock wise and close the bleed valve Then release the lever Repeat this operation until no more air can be seen coming out into the plastic A Hold the brake lever applied B Quickly open and close the bleed valve C Release the brake lever e Repeat the previous step one more time for the other front disc brake e When air bleeding is finished check that the fluid level is between the upper and lower level lines e Install the diaphragm and reservoir cap e Tighten the bleed valve s to the specified torque Torque 7 8 N m 0 80 kgf m 69 in Ib e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Rear Brake Fluid Rear Brake Fluid Level Inspection e With the rear brake fluid reservoir held hor izontal check that the fluid level is between the upper and lower level lines PREPARATION 31 A Rear Brake Fluid Reservoir B Cover C Upper Level Line D Lower Level Line e f the fluid level in the reservoir is lower than the lower level line check for
10. 25 in the same way as the front shift pedal v A Front Shift Pedal B Bolt D 8 L 25 C Align the Punched Marks D Rear Shift Pedal E Shift Shaft Front Footboard Left NOTE OInstall the left footboard after the Clutch Fluid section in the Preparation chapter e Install the left footboard assembly on the frame with one bolt D 10 L 30 at the rear and tighten it wo278017 P A Front Footboard Left B Bolt Rear NOTE OThe bolt in front is for tightening the footboard and the front guard together O Tighten the front footboard mounting bolts af ter installing the front guards to the specified torque Front Guards Left and Right Front Guards Installation e Remove the front side mounting bolt from the front right footboard W 328004 P A Front Footboard Right B Bolt ASSEMBLY 15 e Install both front left and right guards on the frame with the upper mounting bolts D 10 L 25 and on the front footboard brackets with the lower mounting bolts D 10 L 30 a s A Front Guard Left B Bolt D 10 L 25 C Bolt D 10 L 30 D Footboard Bracket e Tighten the front footboard and the guard mounting bolts to the specified torque Torque 34 N m 3 5 kgf m 25 ft lb Label Installation for US and CN Mod els only e Wipe off any oil or grease from the application area e Peel the warning label off the backing she
11. 3 5 kgf m 25 ft lb e Push the large plastic plugs 4 into the han dlebar clamp bolts A Plastic Plugs B Handlebar Clamps Throttle Grip and Right Switch Housing Alignment Pin Type e Apply a light coat of grease on the exposed portion of the throttle inner cables e Fit both throttle cable tips into the nearest socket in the throttle grip A Front Half Right Switch Housing B Throttle Cable Accelerator C Cable Tips Apply Grease D Throttle Grip E Throttle Cable Decelerator F Rear Half Right Switch Housing e Fit the two halves of the right switch housing so that the pin on the front half fits into the hole in the handlebar A Hole B Pin C Front Half e Insert the two screws D 5 L 25 and tighten them e Tighten the holder screw e Check that the throttle grip moves smoothly from full open to close and the throttle closes quickly and completely A Right Switch Housing B Screws L 25 C Harness D Throttle Cable Accelerator E Throttle Cable Decelerator F Holder Screw Front Brake Master Cylinder e Connect the right switch housing lead con nectors to the front brake light switch termi nals on the front brake master cylinder e Apply silicone grease or PBC grease to the master cylinder clamp bolts e Install the front master cylinder with its clamp and the two socket bolts D 6 L 20 F E 2st P A Front Ma
12. Battery F 15 A Fuse Holder G Run the positive cable through the guide in the right side of the battery case e Pull the battery positive cable downward and through the guide in the right side of the battery case and then route the cable as shown e Reinstall the 15 A fuse holder and the battery holder and then install the black diagnosis 4 P connector on the holder and connect the 6 P connector and fasten the harness with the plastic clamp A Pull the Positive Cable downward B Positive Cable C Battery D 4 P Connector Diagnosis E 6 P Connector Rear Harness 15 A Fuse Holder Wiring Clamp 3 P Connector 2 P Connector J 1 P Connector Negative Lead K Negative Cable e Connect the 1 P 2 P and 3 P connectors and fasten the harness of the 2 P and 3 P connectors with the wiring clamp e First connect the red capped positive cable to the positive terminal and then connect the negative cable to the negative termi nal e Put a light coat of grease on the terminals to prevent corrosion e Cover the terminal with its protective cap and install the battery holder nuts and tighten them F G H NOTE OInstall the right side cover after the Coolant section in the Preparation chapter Viewed from Right MLrO2034B51 C A Positive Terminal B Battery C Positive Cable D ECU Relay E Negative Cable Viewed from Top
13. Clamps Deflectors Left and Right Installation e Assemble the left and right stays deflectors and outer plates with the socket bolts D 6 L 16 4 and cap nuts D 6 4 MD43002B51 C A Stay Left B Deflector C Outer Plate D Socket Bolts D 6 L 16 E Stay Right F Cap Nuts e Install each deflector on the bracket with the socket bolts D 8 L 10 2 for each side i A 4 J MD438004 P A Deflector Right B Socket Bolts D 8 L 10 Windshield Height Adjustment The windshield can be adjusted 50 mm 2 in in height to suit the rider s preference e Loosen both the upper and lower bolts on each lower side of the windshield and move it up or down e Align both the left and right windshield stays e Tighten the bolts securely z hg A Windshield B Bolts C Positioning Marks Sub windshield Adjustment e Loosen the windshield bolts on the left and right vertical outer plates and move the sub windshield up or down The distance should be 10 mm 0 04 in between the lower edge of the sub windshield and the headlight body e Tighten the windshield bolts A Bolts B Sub windshield License Plate Bracket License Plate Bracket Installation e Install the license plate bracket onto the rear fender with the bolts D 6 L 12 2 i A Rear Fender B License Plate Bracket C Bolts D 6 L 12 Rear Reflectors and License Plat
14. D 5 on each C W0378002 P A Front Brake Hose Clamp Left B Front Brake Hose Clamp Right C Front Reflectors D Nuts 12 ASSEMBLY Front Fender Installation e Lift the motorcycle off the crate base and sup port the motorcycle with a suitable stand or jack e Loosen the axle clamp bolts on the right fork leg and remove the front axle e Loosen the two flanged bolts D 10 L 47 to remove each front brake caliper A Front Brake Calipers B Flanged Bolts D 10 L 47 CAUTION Do not leave the calipers hanging by the brake hoses After removing the calipers secure them to the frame using a suitable band e Install the front fender with its more rounded end facing forward A Front Fender B Forward e Install the front fender on the fork legs and in stall the front left and right brake hose clamps on the inside of the fender with the four bolts D 8 L 35 and tighten them US and CN Models A Front Fender B Bolts D 8 L 35 C Brake Hose Clamp Left Other than US and CN Models MDO4002B51 C A Front Fender B Bolts D 8 L 35 C Brake Hose Clamp Left Front Wheel Installation e Check the wheel rotation mark on the front tire NOTE OThe direction of the wheel rotation is shown by an arrow on the front tire Install the wheel so that the rotation mark coincides with wheel rotational direction ASSEMBLY
15. Pump M Harness Fuel Gauge e Remove the 15 A fuse holder from the battery holder then remove the battery holder A Battery Holder B 15 A Fuse Holder C Projection D Screwdriver e Take the battery out of the battery case e Clean the terminals Battery Specifications Make Furukawa Battery Type FTZ16 BS Battery Capacity 12 V 18 Ah Electrolyte Capacity 0 82 L Battery Electrolyte Set P No 26012 1371 Battery Activation Filling the Battery with Electrolyte CAUTION Do not remove the aluminum sealing sheet A from the filler ports B until just prior to use Be sure to use the ded icated electrolyte container for correct electrolyte volume e Place the battery on a level surface e Check to see that the sealing sheet A has no peeling tears or holes in it e Remove the sealing sheet A NOTE OThe battery is vacuum sealed If the sealing sheet has leaked air into the battery it may require a longer initial charge SPOBOUO3BST C e Remove the electrolyte container from the vinyl bag e Detach the strip of caps A from the container and set aside these will be used later to seal the battery NOTE ODo not pierce or otherwise open the sealed cells B of the electrolyte container Do not attempt to separate individual cells MEO2006BS1 C e Place the electrolyte container upside down with the six sealed cells
16. RR ERI ERR C A 17 HGF 1 die fi ei f dd f d Pe ad 17 CHOKE Knob aen eb natae etebetedetetesefus 18 Rear View Mirrors Left and Right 18 Windshield 5 2 ien cle bide eh ib eh ibis 19 License Plate Bracket sssssssssessssesseeseessssseeeseeeeeeeseeeeeee 21 Rear Reflectors and License Plate Holder 21 Left Saddlebags ic 5 ete dete te etu Dre ieee 22 Brake Disc Cleaning eesseessesneeeeeneeennnn nne 24 Preparation gu dun ut d das 24 Battery Service sesssssssssssssssssseeeeeeeenene enema 24 Front Brakes FUG outre OO 30 Rear Brake Fluid eee e e 31 CIEN FIU senet tont atten tte tet teeta 32 Rear Shock Absorber essen 34 Tire Air Pressures enne 34 puel ciiin nO EDT E E E T iet 34 GOO a raaa aiana 34 Engine Oil 4 stroke ssssssesem 35 Final Gear Case Oil ssessssesssseeeeeereen enn 36 Throttle Grip and Cabl ss ssr e e a e e an e ee eie 37 Headlight Aim cccccceccccececeeeeeeeeeeeeeccceeeeeeeeeeeeesneeeeeeeeeeeeenaaes 38 Idle Speed Adjustment ssssssssssssenee 38 Rear Brake Light Switch 38 Fastener Check oa ae nana e na AAEE AARAA AARAA aae e n 40 Standard Torque Table cccceeeeeeeeeeeeeeeeneeeeeeeeeeeeeeneeeeeeeeeete 42 Test Ride the Motorcycle 0 ccccceeeeceeeeeeeeeenneeeeeeeeetesenneeeeees 42 A amp P Check List ono io e
17. Windshield LH amp RH Trim Windshield Clamp Trim Socket Bolt Stay Bracket Windshield LH amp RH Socket Bolt Bracket Upper Socket Bolt Bracket Lower Outer Plate Deflector LH amp RH Deflector LH amp RH Stay LH amp RH Socket Bolt with Washer Cap Nut Socket Bolt Stay S OANSANANAS Ws HO2N 5 238 CN AUS only R only D 6 L 25 L 1 900 EUR only 13 Saddlebag LH Lock Saddlebag Damper Bottom Damper Upper Flanged Collar Flanged Bolt Saddlebag Flat Washer Saddlebag Black Battery Electrolyte FTZ16 BS Located in the left side cover Large D 12 D 12 L 13 1 D 8 L 75 D 8 5 x 20 T 1 6 14 Owner s Manual SlI IRMONMNNMNA AIR BRBNNNINNNM FNM AUS Australian Model CN CN Model EUR US European Model United States Model 8 ASSEMBLY Assembly Handlebar NOTE OPosition the handlebar clamp on the handle bar with the slanted side facing rearward e Set the handlebar to match its punched mark to the rear portion of the lower clamp mating face and install the upper clamps and bolts D 10 L 23 E L3 A Front Bolts B Slanted Side C Gap D Punched Mark E No Gap F Forward Handlebar Clamp Bolt Tightening e Tighten the front clamp bolts first and then the rear clamp bolts to the specified torque There will be a gap at the rear part of the clamp after tightening Torque 34 N m
18. fluid leaks in the brake line and fill the reservoir e Loosen the bolt to remove the cover from the reservoir e Remove the reservoir cap and diaphragm and fill the reservoir to the upper level line with DOTA brake fluid CAUTION Brake fluid quickly ruins painted sur faces Wipe up any spilled fluid immedi ately NOTE OFirst tighten the rear brake fluid reservoir cap clockwise by hand until slight resistance is felt indicating that the cap seated on the reser voir body then tighten the cap an additional 1 6 turn while holding the brake fluid reservoir body TK17023B S A Reservoir B Cap C Clockwise D 1 6 turn 32 PREPARATION e Operate the brake lever several times e f it feels spongy there might be air in the brake line e f necessary bleed the air in the rear brake line e Also check for fluid leakage around the fit tings Rear Brake Line Air Bleeding e Remove the rear brake reservoir cap and di aphragm and check that there is plenty of fluid in the reservoir NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be repeated from the beginning since air will have entered the line e Attach a clear plastic hose to the bleed valve on the rear brake caliper and run the other end of the hose into a contain
19. in the saddlebag e Push the flanged collars 2 into the damper W348003 P A Upper Damper B Collars Left Saddlebag Installation NOTE OOnly use the flat washers T 1 6 mm 4 to adjust the clearance 1 0 mm 0 04 in or more between the saddlebag upper dampers and the bracket as needed e While aligning the protrusions on the bottom of the saddlebag with the holes in the lower bracket engage the hook on the back of the saddlebag with the upper bracket then push it down A Saddlebag B Protrusion C Hook D Upper Bracket 24 PREPARATION e Measure the clearances between both the front and rear upper dampers and the up per mounting bracket with the saddlebag lightly pushed by hand against the mounting bracket e f the clearance is 1 0 mm 0 04 in or more at the front and or rear adjust it Insert one or two flat washer s between the upper damper and the mounting bracket until it is less than 1 0 mm 0 04 in at the front and or rear A Saddlebag B Top Stay C Upper Bracket D Upper Dampers E Clearance F Flat Washer G Bolts e f the clearance is less than 1 0 mm 0 04 in at the front and or rear the flat washer is unnecessary e Open the saddlebag lid and install the flanged bolts D 8 L 75 2 through the flat washer s if necessary and tighten them se curely A Left Saddlebag B Bolts D 8 L 75 e After the saddlebag i
20. into the filler ports of the battery Hold the container level push down to break the seals of all six cells You will see air bubbles rising into each cell as the ports fill NOTE ODo not tilt the electrolyte container gum SPOBOUTDSSTI C e Check the electrolyte flow e f no air bubbles A are coming up from the filler ports or if the container cells have not emptied completely tap the container B a few times SPOBOUTDOST C e Keep the container in place for 20 minutes or more Don t remove the container from the battery until it s empty the battery requires all the electrolyte from the container for proper operation CAUTION Removal of the container before it is completely empty can shorten the ser vice life of the battery Do not remove the electrolyte container until it is com pletely empty and 20 minutes have elapsed e Gently remove the container from the battery elet the battery sit for 60 minutes prior to charging to allow the electrolyte to permeate into the plates for optimum performance PREPARATION 27 NOTE OCharging the battery immediately after filling can shorten service life Let the battery sit for at least 60 minutes after filling Initial Charge e Place the strip of caps loosely over the filler ports SPOBOUTBBSTI C A Strip e Newly activated sealed batteries require an initial charge Standard Charge 1 8 A x 5 10 hours e f using a r
21. 0 kgf m 78 in Ib TK050038 G A Oil Drain Plug e Reinstall the saddlebags See Left Saddle bag section in the Assembly chapter Throttle Grip and Cable Throttle Grip Free Play Inspection e Inspect the throttle grip free play If the free play is incorrect adjust the throttle cables Throttle Grip Free Play 2 3 mm 0 08 0 12 in e Check that the throttle grip moves smoothly from full open to close and the throttle closes quickly and completely in all steering posi tions by the return spring If the throttle grip does not return properly check the throttle ca ble routing grip free play and for possible ca ble damage Then lubricate the throttle ca bles PREPARATION 37 WElIBoOIg P A Throttle Grip B 2 3 mm 0 08 0 12 in e Run the engine at idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change If the idle speed increases check the throttle grip free play WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condi tion Throttle Grip Free Play Adjustment e Loosen both locknuts of the throttle cables and turn both adjusters in completely to give the throttle grip plenty of play e Turn out the decelerator cable adjuster until there is no play when the throttle grip is com pletely closed Tighten the locknut A Accelerator Ca
22. 13 A Front Tire B Arrow C Rotation e Fit the axle collars on both sides of the front wheel hub The collars are identical e Put the front wheel assembly between the fork legs e Insert the front axle from the right side of the wheel and push it completely through i Ub ta a A Front Axle B Collar Right C Axle Clamp Bolts Right D Collar Left e Tighten the front axle to the specified torque Torque 108 N m 11 0 kgf m 80 ft Ib e Temporary install the front brake calipers e Before tightening the axle clamp bolts on the right fork leg pump the front fork up and down 4 or 5 times to align the right front fork leg and to seat the front axle Do not pull the brake lever when pumping the fork NOTE ODo not apply the front brake during this process to stop the motorcycle from rolling forward Put a block in front of the front wheel to prevent movement A Pump the fork up and down B Block e Tighten the axle clamp bolts on the right fork leg to the specified torque Torque 29 N m 3 0 kgf m 21 ft Ib NOTE OTighten the two front axle clamp bolts alter nately two times to ensure even tightening torque e Check the clearance between the right fork leg and the axle collar with a thickness gauge There should be about 2 0 mm 0 08 in of clearance The clearance between 1 05 3 19 mm 0 04 0 13 in is acceptable A Right Fork Leg B Front Axle C Axle Cl
23. 8 0 60 0 80 in Ib 8 14 49 14 1 9 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 74 100 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 33 165 240 Test Ride the Motorcycle e Complete the test ride checklist Control Throttle control cables must Cables work without binding in any steering position Steering Action is free from lock to lock Suspension Check operation front and rear Engine Electric starter works properly and engine starts promptly Good throttle response and return Transmission Smooth operation and Clutch Brakes Adequate smooth stopping power No drag Speedometer Check operation Electrical System Headlight check high and low beams Taillight check operation Brake Light check operation Turn Signal Lights check operation Horn check operation Instrument Lights and Indicator Lights Check operation Engine Stop Switch Works Starter Interlock Switch Works No Unusual Noises No Fuel Oil Brake Fluid Clutch Fluid or Coolant Leaks PREPARATION COMPLETE A WARNING New tires are slippery and may cause loss of control and injury A break in pe riod of 160 km 100 miles is necessary to establish normal tire traction During break in avoid sudden and maxi mum braking and acceleration and hard cornering A amp P Check List e Complete the A amp P Check List
24. G 5 No Part Name Q Z Remarks Handlebar with Grip Handlebar Clamp Clamp Bolt Socket Plastic Plug Clamp Bolt Throttle Grip Clamp Master Cylinder Clamp Bolt Master Cylinder Socket Plastic Plug Clamp Bolt Plastic Clamp Wiring and Hose Screw Switch Housing LH amp RH Rear View Mirror LH amp RH D 10 L 23 Large D 6 L 20 Small L 88 5 D 5 L 25 Front Wheel Axle Collar LH amp RH Front Fender with Brace Socket Bolt Front Fender BRA NM AINA HAH HN A ARAN L 46 5 D 8 L 35 For US and CN Models Brake Hose Clamp LH amp RH Grommet Brake Hose Front Reflector LH amp RH Flanged Nut Reflector For other than US and CN Models Brake Hose Clamp LH amp RH Grommet Brake Hose NM NON ON Front Left Footboard Assembly Flanged Bolt Front Footboard LH Front Guard LH amp RH Flanged Bolt Front Guard Warning Label Front Left Guard Front Shift Pedal Rear Shift Pedal Flanged Bolt Front and Rear Shift Pedals D 10 L 30 D 10 L 2 25 US and CN Models Only D 8 L 25 Rear Guard LH amp RH Flanged Bolt with Washer Rear Guard Upper Socket Bolt Rear Guard Lower Plastic Plug Socket Bolt Rear Guard Flanged Bolt Rear Guard Cap Nut Rear Guard Helmet Lock Screw with Non permanent locking agent Helmet Lock Warning Label Rear Left Guard Backrest Pad Backrest Frame Cover with Mark Backrest Cap Nut Cover Bolt Backrest Frame
25. amp Bolts D About 2 0 mm 0 08 in E Collar Right e f the clearance is out of this range remove the front wheel and check the axle wheel hub and other related parts for damage e Tighten both front brake caliper mounting bolts D 10 L 47 to the specified torque Torque 34 N m 3 5 kgf m 25 ft Ib 14 ASSEMBLY e Check the front brake A Front Brake Caliper Left B Bolts D 10 L 47 A 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 are against the disc The brake will not func tion on the first application of the lever if this is not done Front Brake Hose Grommets e Fit the grommet onto each front left and right brake hose and install it in the clamp US and CN Models A Front Brake Hose Left B Grommet C Brake Hose Clamp Left Other than US and CN Models MD13001B51 C A Front Brake Hose Left B Grommet C Brake Hose Clamp Left Front and Rear Shift Pedals NOTE OInstall the front and rear shift pedals after the Clutch Fluid section in the Preparation chap ter e Install the front shift pedal on the shift shaft aligning the punched marks on the pedal and the shaft e Install the pedal bolt D 8 L 25 and tighten it to the specified torque Torque 30 N m 3 1 kgf m 22 ft Ib e Install the rear shift pedal with the bolt D 8 L
26. ble B Decelerator Cable C Locknuts D Adjusters e Turn out the accelerator cable adjuster un til the specified amount of play is obtained Tighten the locknut 38 PREPARATION Headlight Aim The headlight beam is adjustable both hori zontally and vertically Headlight aim must be correctly adjusted for safe riding as well as on coming drivers In most areas it is illegal to ride with an improperly adjusted headlight Horizontal Adjustment e Turn the horizontal adjusting screw on the headlight rim in or out until the beam points A Horizontal Adjusting Screw B Vertical Adjusting Screw Vertical Adjustment e Turn the vertical adjusting screw on the head light rim in or out to adjust the headlight verti cally NOTE OOn high beam the brightest point should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper angle according to local regulation Idle Speed Adjustment e Start the engine and warm it up thoroughly e Adjust the idle speed to 900 1 000 r min rpm by turning the idle adjusting screw Idle Speed 900 1 000 r min rpm oS A Idle Adjusting Screw e Open and close the throttle grip a few times to make sure that the idle speed does not change e With the engine idling turn the handlebar to each side If handlebar movement changes the idle speed check the throttle cable routing and free play A WARNING Op
27. e Minimum Octane Rating Method Rating Antiknock RON MON 90 Index 2 Research Octane Number 95 RON e Close the fuel tank cap and check for any leaks Coolant Coolant Level Inspection e Situate the motorcycle so that it is perpendic ular to the ground e Check the coolant level through the coolant level gauge The coolant level should be be tween the F Full and L Low marks NOTE OCheckthe level when the engine is cold room or atmospheric temperature TK040138 G A F Full Mark B L Low Mark C Right Side Cover Coolant Filling e f the amount of coolant is insufficient remove the right side cover pull open the cap from the reserve tank and add coolant through the filler opening to the F Full mark A Cap B F Full Mark C L Low Mark e Install the cap e To install the right side cover insert the pro jections into the grommets e Tighten the screw A Right Side Cover B Projections C Grommets PREPARATION 35 NOTE OA permanent type of antifreeze is installed in the cooling system when shipped It is col ored green and contains ethylene glycol It is mixed at 50 and has the freezing point of 35 C 31 F Engine Oil 4 stroke Engine Oil Level Inspection NOTE OThis vehicle s engine is filled with 10W 40 oil from the factory DO NOT DRAIN and refill the crankcase before use Check oil level and d
28. e Holder US and CN Models only e Assemble the rear reflectors bracket and li cense plate holder with the cap nut D 5 on each ASSEMBLY 21 MD37000B51 C A Reflectors B Reflector Bracket C License Plate Holder D Cap Nuts D 5 e Install the license plate holder and the rear reflector bracket on the license plate bracket with the bolts D 6 L 14 3 and plated cap nuts 3 and tighten them The remaining fasteners are used for the license plate MD2400B8B51 C A License Plate Holder B Reflector Bracket C Bolt D 6 L 14 D Cap Nut E License Plate Bracket F For US Models G For CN Models AUS Models only e Install the rear reflector on the license plate holder with the cap nut D 5 and tighten it 22 ASSEMBLY MD37001B51 C MD24008B51 C A Reflector B License Plate Holder C Cap Nut D 5 e Install the license plate holder on the license plate bracket with the bolts D 6 L 14 3 and plated cap nuts 3 and tighten them The remaining fasteners are used for the license plate MD24007B51 C A License Plate Holder B Bolt D 6 L 14 C Cap Nut D License Plate Bracket Other than US CN and AUS Models only e Install the license plate holder on the license plate bracket with the bolts D 6 L 14 3 and plated cap nuts 3 and tighten them The remaining fasteners are used for the license plate
29. e into a container e With the reservoir cap off slowly pump the clutch lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reservoir This bleeds the air from the clutch master cylinder end of the line e Pump the clutch lever a few times until it becomes hard and then holding the lever squeezed quickly open turn counterclock wise and close the bleed valve Then release the lever Repeat this operation until no more air can be seen coming out into re i E os H A Hold the clutch lever applied B Quickly open and close the bleed valve C Release the clutch lever e When air bleeding is finished check that the fluid level is between the upper and lower level lines e Install the diaphragm and reservoir cap e Tighten the bleed valve to the specified torque Torque 7 8 N m 0 80 kgf m 69 in Ib e Apply the clutch forcefully for a few seconds and check for fluid leakage around the fittings e Apply a soap and water solution or rubber lubricant to the body of the alternator cover bolts for easy installation e Reinstall the alternator outer cover with the bolts and washers and tighten the bolts to the specified torque Torque 6 9 N m 0 70 kgf m 61 in Ib e Reinstall the front and rear shift pedals See Shift Pedal section in the Assembly chapter e Reinstall the left footboard assembly See Front Footboard Left section in the Assem
30. ecommended battery charger fol low the charger s instructions for newly acti vated sealed battery Kawasaki recommended chargers Optimate lll Yuasa 1 5 Amp Automatic Charger Battery Mate 150 9 e f the above chargers are not available use equivalent one NOTE OCharging rates will vary depending on how long the battery has been stored tempera ture and the type of charger used Let battery sit 60 minutes after initial charge then check voltage using a voltmeter If it is not at least 12 6 volts repeat charging cycle e After charging is completed press down firmly with both hands to seat the strip of caps A into the battery don t pound or ham mer When properly installed the strip of caps will be level with the top of the battery 28 PREPARATION SPOBOUTODTSTI C CAUTION Once the strip of caps A is installed onto the battery never remove the caps nor add water or electrolyte to the bat tery NOTE OTo ensure maximum battery life and customer satisfaction it is recommended the battery be load tested at three times its amp hour rating for 15 seconds Re check voltage and if less than 12 6 volts repeat the charging cycle and load test If still below 12 6 volts the battery is defective Battery Installation e Turn the ignition switch OFF e Place the battery into the battery case A Negative Cable B Positive Cable C Battery Holder D Plastic Clamp E
31. er e With the reservoir cap off slowly pump the brake pedal several times until no air bub bles can be seen rising up through the fluid from the holes at the bottom of the reservoir This bleeds the air from the rear brake master cylinder end of the line e Pump the brake pedal a few times until it becomes hard and then holding the pedal pushed down quickly open turn counter clockwise and close the bleed valve Then release the pedal Repeat this operation until no more air can be seen coming out into the plastic hose i A Hold the brake pedal applied B Quickly open and close the bleed valve C Release the brake pedal e When air bleeding is finished check that the fluid level is between the upper and lower level lines e Tighten the bleed valve s to the specified torque Torque 7 8 N m 0 80 kgf m 69 in Ib e Install the diaphragm and reservoir cap NOTE OFirst tighten the rear brake fluid reservoir cap clockwise by hand until slight resistance is felt indicating that the cap seated on the reser voir body then tighten the cap an additional 1 6 turn while holding the brake fluid reservoir body e Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings e Install the cover with the bolt Clutch Fluid Clutch Fluid Level Inspection e With the clutch reservoir held horizontal check that the fluid level is above the lower level line A Clutch Fl
32. eration with improperly routed or damaged throttle cables could result in an unsafe riding condition e Check for any exhaust leaks and correct if necessary Rear Brake Light Switch Rear Brake Light Switch Adjustment e Turn on the ignition switch The brake light should illuminate when the brake pedal is de pressed about 10 mm 0 4 in TK180288 G A Brake Pedal B 10 mm 0 4 in e f it does not turn the adjusting nut at the rear brake light switch as required A Rear Brake Light Switch B Adjusting Nut C Lights sooner D Lights later CAUTION To avoid damaging the electrical con nections inside the switch be sure that the switch body does not turn during ad justment PREPARATION 39 40 PREPARATION Fastener Check e The torque values listed are for assembly and preparation items only see the appropriate Service Manual for a more comprehensive list Check tightness of all fasteners that are in the table before retail delivery Also check to see that each cotter pin or circlip is in place PREPARATION 41 Torque No Fastener Remarks N m kgf m ft lb Steering 1 Handlebar clamp bolts 34 3 5 25 2 Steering stem head nut 88 9 0 65 Brake TT 3 Front master cylinder clamp bolts 4 Front caliper mounting bolts Left and Right 34 3 5 25 5
33. et and stick it on the center of the front left guard A Front Guard Left B Label For US Models 56070 1285 C Label Top D Label For CN Models 56070 1180 16 ASSEMBLY Helmet Locks e Unlock the helmet lock with the key and fit the small projection of the lock into the hole in the bracket of each rear guard and fasten it with the screw D 5 L 12 having a non permanent locking agent e Lock the helmet lock A Helmet Lock B Ignition Key C Projection D Screw E Rear Guard Left Rear Guards Left and Right Rear Guards Installation e Remove the right saddlebag e Insert the ignition key into the lock and turn the key counterclockwise and pull the knob outward to open the lid A Saddlebag Right B Ignition Key C Counterclockwise D Knob e Open the saddlebag lid and remove the bolts D 8 L 75 inside the saddlebag and then pull it up Bolts D 8 L 75 e Join the rear left guard end and the left sad dlebag muffler bracket with the bolts D 8 L 35 2 and cap nuts 2 and tighten them e Install the guard on the brackets with the up per bolt D 10 L 30 and the lower socket bolt D 10 L 50 and tighten them A Rear Guard Left B Bolts D 8 L 35 and Cap Nuts C Bolt D 10 L 30 D Socket Bolt D 10 L 50 e Push the large plastic plug into the top of the socket bolt A P
34. h if not correctly followed could result in dam age to or destruction of equipment NOTE OThis note symbol indicates points of particular interest for more efficient and convenient op eration Kawasaki Heavy Industries Ltd accepts no liability for any inaccuracies or omissions in this publication although every possible measure has been taken to make it as complete and ac curate as possible All procedures and specifi cations subject to change without notice Nov 2004 K Table of Contents Uncr ting 1 ditti tiit tui tdt du ddl dada dad 3 Opening Crate sssssssssssseeeeeem eene nnn 3 Parts Check sess 4 Assembly rre REV YEEEFEE EYE EYE ELE PERI 8 Handlebars tnnt iia 8 Throttle Grip and Right Switch Housing sssssssse 8 Front Brake Master Cylinder sseeeee 9 Left Switch HOUSING aineet taata aiseta 9 Clutch Master Cylinder ssssse 10 Wiring Clamps miserae aana a a aaa a nnne 10 Front FENIE aari EERE 11 Front Wheel InstalatiOn sssusa nsnsi iea 12 Front Brake Hose Grommets cceceeeeeeeeeeeeeneeeeeeeeeeeeeaaes 14 Front and Rear Shift Pedals esses 14 Front Footboard Left sseesssessseeeeeeennnn 15 Front Guards Left and Right sesssssssss 15 Helmet LOCKS naaa aaa EEA A AAAA 16 Rear Guards Left and Right 16 BackrestPada uoti tenti Ran
35. h hous ing to the starter lock out switch on the master cylinder e Tighten the upper clamp bolt first and then the lower bolt to the specified torque Torque 11 N m 1 1 kgf m 97 in Ib e Push the small plastic plugs 2 into the clutch master cylinder clamp bolts Mo0o5021 P A Plastic Plugs B Clutch Master Cylinder Wiring Clamps e Fasten the front brake hose and the right Switch housing harness to the right side of the handlebar with two plastic clamps NOTE OThe plastic clamp at the inside fastens the right switch harness only jy ISON P A Handlebar Right Side B Plastic Clamps C Front Brake Hose D Right Switch Harness e Fasten the clutch hose and the left switch housing harness to the left side of the han dlebar with two plastic clamps Woi38014 P A Handlebar Left Side B Plastic Clamps C Clutch Hose D Left Switch Harness ASSEMBLY 11 Wb dDZ4EN2 A Left Switch Lead B Clutch Hose C 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 Cables G Brake Hose H Right Switch Lead l Handlebar Front Fender A Front Reflectors for US and CN Models only e Assemble the front left and right reflectors and the brake hose clamps with the nut
36. i lt VULCAN 1600 NOMAD I Kawasaki VN1600 CLASSIC TOURER Motorcycle Assembly amp Preparation Manual Foreword In order to ship Kawasaki vehicles as effi ciently as possible they are partially disassem bled before crating Since some of the most commonly removed parts have a direct bear ing on a vehicle s reliability and safety consci entious pre sale assembly and preparation be comes extremely important Good setup pro cedures can prevent needless warranty claims and give customers a greater sense of confi dence in Kawasaki and their Kawasaki Dealers This Assembly and Preparation Manual ex plains step by step procedures of the following items for all Kawasaki motorcycles 1 Uncrating 2 Assembly 3 Preparation The selling dealer assumes sole responsibil ity for any unauthorized modifications prior to sale Refer to your Service Binder for any Ser vice Bulletins specifying Factory Directed Mod ifications Special Claims which must be per formed before the vehicle is ready for sale Whenever you see the following symbols heed their instructions Always follow safe operating and maintenance practices 2004 Kawasaki Heavy Industries Ltd A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or less of life CAUTION This caution symbol identifies special instructions or procedures whic
37. ightening B Upper Hexagonal Area Adapter C Stay D Non permanent Locking Agent applied e Turn the stay to assure visibility to the rear with the operator sitting on the motorcycle e Adjust the rear view mirror by slightly moving only the mirror portion of the assembly LULA A Stay B Mirror e Installation and adjustment of the right side mirror is common with the left side Follow the procedure specified for the left side Windshield CAUTION Be sure not to damage the surface of the windshield when installing or handling ASSEMBLY 19 A Windshield Assembly e Remove the dummy bolts on the fork cover and discard them o X WO A Fork Cover B Dummy Bolts Right Side e Install the left and right mounting brackets on the fork cover with the socket bolts D 8 L 20 D 8 L 25 L E A Mounting Bracket Right B Socket Bolt D 8 L 20 C Socket Bolt D 8 L 25 e Install the windshield assembly on the mount ing brackets with the socket bolts D 8 L 10 4 e Set the windshield all the way down and tighten the bolts securely 20 ASSEMBLY fi y Bj Ke A TG230008 G A Windshield Assembly B Socket Bolts D 8 L 10 Trim Installation EUR Models Only e Fit the windshield trim onto the edge of the windshield starting from each lower edge e Fix the trim ends with the clamps 2 amp 016002B51 C A Trim B
38. io ato adieu aite eds 42 Uncrating Opening Crate e Clear a space about 6 m 20 ft square to give yourself plenty of space to work e Place the crate upright on its base e Remove the cardboard cover e Remove the handlebar front wheel and the parts box CAUTION When you remove the crate bracket from the motorcycle be careful not to drop any parts and bracket onto the fuel tank and other components and not to scratch the fuel tank by the crate bracket This could damage the fuel tank or components e Unscrew the four bolts to remove the front brake and clutch master cylinders e Remove the two bracket bolts and the crate bracket and discard them A Bolts B Bolt C Front Master Cylinder D Crate Bracket E Clutch Master Cylinder e Unscrew the two lower bolts and then re move the two upper bolts and crate bracket Discard the bolts and bracket UNCRATING 3 r A Lower Bolts B Upper Bolts C Crate Bracket e Take out all the bolts and screws and remove the top and sides of the crate 4 UNCRATING Parts Check e Open the parts box and check the parts against the illustrations There may be minor differences between 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 millimeters WCOSDSSRE4 UNCRATIN
39. lastic Plug B Rear Guard Left e Install the right guard in the same manner as the left guard Label Installation for US and CN Mod els only e Wipe off any oil or grease from the application area e Peel the warning label off the backing sheet and stick it on the rear left guard p A Rear Guard Left B Label For US Models 56070 1285 C Label Top D 20 mm 0 8 in E Label For CN Models 56070 1180 NOTE OReinstall the right saddlebag after the Rear Brake Fluid and Rear Shock Absorber sec tions in the Preparation chapter When in stalling the right saddlebag see Left Saddle bag section in the Assembly chapter Backrest Pad e Assemble the backrest pad frame and cover with the cap nuts D 6 4 MD26001B51 C A Backrest Pad B Cover C Cap Nut D 6 D Frame ASSEMBLY 17 e Install the backrest between the brackets with the flanged bolts D 8 L 50 4 and the cap nuts D 8 e Tighten all the bolts and nuts securely Eh A Backrest B Cap Nuts D 8 C Bolts D 8 L 50 Horn e Connect the horn lead connectors BK BK of the harness to the horn terminals at the left side of the radiator A Horn B Connectors BK BK C Bracket e Install the horn with bracket to the frame with the bolt D 8 L 12 and tighten it 18 ASSEMBLY A Horn B Bolt D 8 L 12 C Bracke
40. most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area r1 l L SAE 20W 50 20 10 10 20 30 40 70 a 4 14 a 880 58 BE T 4CTF p Q1 TK03023BZ2 Final Gear Case Oil Final Gear Case Oil Level Inspection e Have a helper hold the motorcycle vertical on level ground e Remove the filler cap e Check the oil level If it is low add oil as necessary The oil level should come to the bottom thread of the filler opening with the motorcycle held vertical on level ground b E A Bottom Thread B Filler Cap e f the oil level is too low add the specified oil e f the oil level is too high remove the excess oil using a syringe or some other suitable device A WARNING Be careful that no oil gets on the tire rim and brake disc Clean off any oil that inadvertently gets on them with oilless solvent CAUTION Be careful not to allow any dirt or foreign materials to enter the gear case NOTE OUse the same type of oil that is already in the final gear case e 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 9
41. rain plug tightness Engine Oil Drain Plug Torque 20 N m 2 0 kgf m 14 ft Ib TK03026B G A Oil Drain Plug e Park the vehicle on level ground e Before starting the engine check that the en gine has oil e Check that the engine has oil through the oil level sight gauge in the lower right side of the engine CAUTION If the engine is run without oil it will be severely damaged e Start the engine and run it for several minutes at idle speed Stop the engine then wait sev eral minutes until the oil settles e With the motorcycle held level check the en gine oil level through the oil level sight gauge The oil level should come up between the H High and L Low level lines next to the gauge 36 PREPARATION A Oil Filler Cap B Oil Level Sight Gauge C H High Level Line D L Low Level Line e If the oil level is too high remove the excess oil through the oil filler opening using a sy ringe or some other suitable device e If the oil level is too low add oil to reach the correct level Use the same type of oil that is already in the engine e When replacing the cap be sure the O ring is in place and tighten the cap Recommended Engine Oil Type API SE SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 2 9 L 3 1 US qt when filter is not removed 3 1 L 3 3 US qt when filter is removed Although 10W 40 engine oil is the recom mended oil for
42. s installed open and close the lid several times and check for smooth movement of the lid handle and lid lock operation If they operate improperly remove the bolts and readjust the clearance e Install the right saddlebag in the same man ner as the left saddlebag Brake Disc Cleaning e Clean the front and rear brake discs using oilless solvent A WARNING If not removed the anticorrosive treat ment applied to the brake disc surface will interfere with brake action and an unsafe riding condition could result Preparation Battery Service The battery used in this motorcycle is a sealed type and never needs to be refilled Follow the procedure for activating a new battery to ensure the best possible battery performance Activating the battery requires two steps fill ing the battery with electrolyte and charging Read the electrolyte safety label and the follow ing procedures carefully before battery activa tion CAUTION Incorrect Battery Activation will reduce battery performance and service life Be sure to strictly follow the Battery Service instructions in this Manual e Make sure to use the electrolyte packed in the crate with the unit e Make sure that the model name of the elec trolyte container matches the model name of the battery These names must be the same Battery Model Name for VN1600 D1 FTZ16 BS PAXXOD 881 A Model Name of the Electrolyte B
43. ster Cylinder B Punched Mark C Clamp D Socket Bolts E Harness F Front Brake Light Switch G Connectors and Dust Covers e Position the master cylinder so that the gap between the front and rear master cylinder clamps aligns with the punched mark on the handlebar e Tighten the upper clamp bolt first and then the lower bolt to the specified torque Torque 8 8 N m 0 90 kgf m 78 in Ib ASSEMBLY 9 e Push the small plastic plugs 2 into the mas ter cylinder clamp bolts A Plastic Plugs B Master Cylinder Left Switch Housing e Fit the two halves of the left switch housing together so that the vertical parting line of the front and rear halves align with the punched mark on the handlebar A Punched Mark B Rear Half Left Switch Housing C Front Half D Screws L 25 E Harness e Insert the two screws D 5 L 25 and tighten them securely 10 ASSEMBLY Clutch Master Cylinder e Apply silicone grease or PBC grease to the master cylinder clamp bolts e Install the clutch master cylinder with its clamp and the two socket bolts D 6 L 20 e Position the master cylinder so that the gap between the front and rear master cylinder clamps aligns with the punched mark on the handlebar A Clamp B Clutch Master Cylinder C Punched Mark D Connector and Dust Cover E Starter Lock out Switch F Harness G Socket Bolts e Connect the connector of the left switc
44. t Choke Knob e Loosen the locknut and fasten the choke knob to the bracket with locknut A Choke Knob B Locknut C Bracket Rear View Mirrors Left and Right Conventional Type Single Nut Loosen the locknut completely e Screw the rear view mirror in completely and then back it two turns out e Turn the mirror stay to assure visibility to the rear with the operator sitting on the motorcy cle and tighten the locknut securely e Adjust the rear view mirror by slightly moving only the mirror portion of the assembly A Locknut B Rear View Mirror Left e Installation and adjustment of the right side mirror is common with the left side Follow the procedure specified for the left side Turning Stay Type e Screw the mounting area of the left rear view mirror into the holder all the way and tighten the lower hexagonal area securely A Lower Hexagonal Area for Tightening B Upper Hexagonal Area Adapter C Rear View Mirror Left CAUTION Do not force to tighten and or loosen the upper hexagonal area adapter with a spanner or wrench Disassembly of this area is not possible Non permanent locking agent is already applied to the threads of this inner area Forcible loos ening may damage the adapter and or the turning mechanism of the stay iH Al iG Ena acd ED f LUE MIN f SS MDi4002BS1 C A Lower Hexagonal Area for T
45. uid Reservoir B Lower Level Line e f the fluid level in the reservoir is lower than the lower level line check for fluid leaks in the clutch line and fill the reservoir NOTE OSince the clutch fluid is the same as the brake fluid refer to the Front or Rear Brake Fluid section for further details e Loosen the screws to remove the clutch fluid reservoir cap and diaphragm e Fill the reservoir to the upper level line with DOTA clutch fluid Inside the clutch reservoir is a stepped line showing the upper level line A Clutch Fluid Reservoir B Upper Level Line e Operate the clutch lever several times e If it feels spongy there might be air in the line e f necessary bleed the air in the lines e Also check for fluid leakage around the fit tings Clutch Line Air Bleeding e Loosen the mounting bolts to remove the al ternator outer cover A Alternator Outer Cover B Socket Bolts and Washers e Remove the reservoir cap and diaphragm and check that there is plenty of fluid in the reservoir NOTE OThe fluid level must be checked several times during the bleeding operation and replenished as necessary If the fluid in the reservoir runs completely out any time during bleeding the bleeding operation must be repeated from the beginning since air will have entered the line PREPARATION 33 e Attach a clear plastic hose to the bleed valve on the clutch slave cylinder and run the other end of the hos
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