VULCAN 1600 NOMAD VN1600 CLASSIC TOURER Motorcycle Assembly & Preparation Manual
Foreword In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some of the most commonly removed parts have a direct bearing on a vehicle’s reliability and safety, conscientious pre-sale assembly and preparation becomes extremely important. Good setup procedures can prevent needless warranty claims and give customers a greater sense of confidence in Kawasaki and their Kawasaki Dealers.
Table of Contents Uncrating ...................................................................................... Opening Crate ............................................................................. Parts Check ................................................................................. Assembly ...................................................................................... Handlebar....................................................................................
UNCRATING 3 Uncrating Opening Crate a space about 6 m (20 ft.) square to • Clear give yourself plenty of space to work. the crate upright on its base. • Place Remove cardboard cover. • Remove the the • parts box. handlebar, front wheel, and the 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.
4 UNCRATING Parts Check the parts box, and check the parts against the illustrations. There may be minor differences • Open 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.
UNCRATING 5 No. Part Name Remarks Qty 1 Handlebar with Grip 1 2 Handlebar Clamp 4 D = 10, L = 23 Clamp Bolt, Socket 4 Large Plastic Plug, Clamp Bolt 1 Throttle Grip 2 Clamp, Master Cylinder 4 D = 6, L = 20 Clamp Bolt, Master Cylinder, Socket 4 Small Plastic Plug, Clamp Bolt 4 L = 88.5 Plastic Clamp, Wiring and Hose 4 D = 5, L = 25 Screw, Switch Housing, LH & RH 2 Rear View Mirror, LH & RH 2 Front Wheel 1 2 L = 46.
6 UNCRATING * : European Models Only
UNCRATING 7 No.
8 ASSEMBLY Assembly Handlebar NOTE żPosition the handlebar clamp on the handlebar with the slanted side facing rearward. the handlebar to match its punched mark • Set to the rear portion of the lower clamp mating Throttle Grip and Right Switch Housing Alignment Pin Type a light coat of grease on the exposed • Apply portion of the throttle inner cables. both throttle cable tips into the nearest • Fit socket in the throttle grip. face and install the upper clamps and bolts (D = 10, L = 23). A.
ASSEMBLY 9 the small plastic plugs (2) into the mas• Push ter cylinder clamp bolts. A. Right Switch Housing B. Screws (L = 25) C. Harness D. Throttle Cable (Accelerator) E. Throttle Cable (Decelerator) F. Holder Screw A. Plastic Plugs B. Master Cylinder Left Switch Housing Front Brake Master Cylinder the right switch housing lead con• Connect nectors to the front brake light switch termi- • • nals on the front brake master cylinder.
10 ASSEMBLY Clutch Master Cylinder silicone grease or PBC grease to the • Apply master cylinder clamp bolts. the clutch master cylinder with its • Install clamp and the two socket bolts (D = 6, L = • 20). 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.
ASSEMBLY 11 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 I. Handlebar Front Fender Front Reflectors (for US and CN Models only) the front left and right reflectors and • Assemble the brake hose clamps with the nut (D = 5) on each. A.
12 ASSEMBLY Front Fender Installation • • • US and CN Models Lift the motorcycle off the crate base and support the motorcycle with a suitable stand or jack. Loosen the axle clamp bolts on the right fork leg and remove the front axle. Loosen the two flanged bolts (D = 10, L = 47) to remove each front brake caliper. A. Front Fender B. Bolts (D = 8, L = 35) C. Brake Hose Clamp (Left) Other than US and CN Models A. Front Brake Calipers B.
ASSEMBLY 13 A. Front Tire B. Arrow C. Rotation A. Pump the fork up and down. B. Block the axle collars on both sides of the front • Fit wheel hub. The collars are identical. the front wheel assembly between the • Put fork legs. the front axle from the right side of the • Insert wheel and push it completely through. the axle clamp bolts on the right fork • Tighten leg to the specified torque. Torque : 29 N·m (3.
14 ASSEMBLY • Check the front brake. Other than US and CN Models A. Front Brake Caliper (Left) B. Bolts (D = 10, L = 47) A. Front Brake Hose (Left) B. Grommet C. Brake Hose Clamp (Left) WARNING Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function on the first application of the lever if this is not done.
ASSEMBLY 15 Front Footboard (Left) NOTE both front left and right guards on the • Install 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). żInstall the left footboard after the “Clutch Fluid” section in the Preparation chapter. the left footboard assembly on the • Install frame with one bolt (D = 10, L = 30) at the rear and tighten it. A. B. C. D. A. Front Footboard (Left) B.
16 ASSEMBLY Helmet Locks the helmet lock with the key and fit • Unlock 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. Lock the helmet lock. A. Bolts (D = 8, L = 75) the rear left guard end and the left sad• Join dlebag/muffler bracket with the bolts (D = 8, L • = 35)(2) and cap nuts (2) and tighten them.
ASSEMBLY 17 Label Installation (for US and CN Models only) off any oil or grease from the application • Wipe area. the warning label off the backing sheet • Peel and stick it on the rear left guard. 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 żReinstall the right saddlebag after the “Rear the backrest between the brackets with • Install the flanged bolts (D = 8, L = 50)(4) and the cap • nuts (D = 8).
18 ASSEMBLY A. Horn B. Bolt (D = 8, L = 12) C. Bracket Choke Knob the locknut and fasten the choke knob • Loosen to the bracket with locknut. A. Locknut B. Rear View Mirror (Left) and adjustment of the right side • Installation mirror is common with the left side. Follow the procedure specified for the left side. Turning Stay Type the mounting area of the left rear view • Screw mirror into the holder all the way, and tighten the lower hexagonal area securely. A. Choke Knob B. Locknut C.
ASSEMBLY 19 A. Lower Hexagonal Area for Tightening B. Upper Hexagonal Area (Adapter) C. Stay D. Non-permanent Locking Agent applied. A. Windshield Assembly the dummy bolts on the fork cover • Remove and discard them. the stay to assure visibility to the rear • Turn with the operator sitting on the motorcycle. the rear view mirror by slightly moving • Adjust only the mirror portion of the assembly. A. Fork Cover B.
20 ASSEMBLY each deflector on the bracket with the • Install socket bolts (D = 8, L = 10)(2) for each side and tighten them. A. Windshield Assembly B. Socket Bolts (D = 8, L = 10) Trim Installation [EUR Models Only] the windshield trim onto the edge of the • Fit windshield starting from each lower edge. • Fix the trim ends with the clamps (2). A. Deflector (Right) B. Socket Bolts (D = 8, L = 10) Windshield Height Adjustment The windshield can be adjusted 50 mm (2 in.
ASSEMBLY 21 A. Bolts B. Sub-windshield A. B. C. D. License Plate Bracket the license plate holder and the rear • Install reflector bracket on the license plate bracket License Plate Bracket Installation • Install the license plate bracket onto the rear fender with the bolts (D = 6, L = 12)(2). A. Rear Fender B. License Plate Bracket C.
22 ASSEMBLY A. Reflector B. License Plate Holder C. Cap Nut (D = 5) the license plate holder on the license • Install 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. A. License Plate Holder B. Bolt (D = 6, L = 14) C. Cap Nut D. License Plate Bracket Left Saddlebag NOTE żInstall the saddlebags after the “Final Gear Case Oil”, “Rear Brake Fluid”, and “Rear Shock Absorber” sections in the Preparation chapter.
ASSEMBLY 23 the saddlebag lid, and insert the upper • Open dampers (2) into the holes in the saddlebag. • Push the flanged collars (2) into the damper. A. Lock B. Left Saddlebag C. Locked-position Mark D. Projections E. Notches NOTE A. Upper Damper B. Collars Left Saddlebag Installation żPush the lid lock all the way into the hole in the lid so that the projection ends are inserted into it. NOTE żOnly use the flat washers (T = 1.6 mm) (4) to adjust the clearance [1.0 mm (0.04 in.
24 PREPARATION the clearances between both the • Measure front and rear upper dampers and the up- the saddlebag is installed, open and • After close the lid several times, and check for per mounting bracket with the saddlebag lightly pushed by hand against the mounting bracket. If 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.
PREPARATION 25 Battery Model Name for VN1600–D1: FTZ16–BS A. Rider’s Seat B. Bolt (D = 6, L = 14) A. Model Name of the Electrolyte B. Model Name of the Battery the screw (D = 6, L = 14) and pull • Remove the right side cover outward to clear the projections. CAUTION Sealed battery electrolyte has a higher concentration of sulfuric acid. Each container contains the proper amount of electrolyte for its specific battery.
26 PREPARATION 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 dedicated electrolyte container for correct electrolyte volume. 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) I. 4 P Connector (Diagnosis) J. Plastic Clamp K. 15 A Fuse Holder L.
PREPARATION 27 the electrolyte container upside down • Place with the six sealed cells 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 żDo not tilt the electrolyte container. the electrolyte flow. • Check If no air [A] are coming up from the • filler ports,bubbles or if the container cells have not emptied completely, tap the container [B] a few times.
28 PREPARATION the battery positive cable (+) downward • Pull and through the guide in the right side of the • battery case, and then route the cable as shown. 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. CAUTION Once the strip of caps [A] is installed onto the battery, never remove the caps, nor add water or electrolyte to the battery.
PREPARATION 29 Viewed from Right A. Positive Terminal (+) B. Battery C. Positive Cable (+) D. ECU Relay E. Negative Cable (–) Viewed from Top Rider’s Seat Installation the projection at the front of the rider’s • Insert seat into the receptacle on the frame. A. Projection B. Receptacle • Install the bolt (D = 6, L = 14) and tighten it. A. Rider’s Seat B. Bolt (D = 6, L = 14) the projection at the front of the passen• Insert ger’s seat into the receptacle on the frame. A. Negative Cable (–) B.
30 PREPARATION A. Bolt (D = 6, L = 14) B. Passenger’s Seat Front Brake Fluid Front Brake Fluid Level Inspection the front brake fluid reservoir held hori• With zontal, check that the fluid level is above the lower level line. A. Front Brake Fluid Reservoir B. Upper Level Line 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.
PREPARATION 31 a clear plastic hose to the bleed valve • Attach on each front brake caliper and run the other • • end of the hose into a container. 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.
32 PREPARATION the brake lever several times. • Operate If it feels • brake line.spongy, there might be air in the • Ifline.necessary, bleed the air in the rear brake check for fluid leakage around the fit• Also tings. Rear Brake Line Air Bleeding the rear brake reservoir cap and di• Remove aphragm, and check that there is plenty of fluid in the reservoir. NOTE żThe fluid level must be checked several times, during the bleeding operation and replenished as necessary.
PREPARATION 33 a clear plastic hose to the bleed valve • Attach on the clutch slave cylinder and run the other • • A. Clutch Fluid Reservoir B. Upper Level Line the clutch lever several times. • Operate If it feels spongy, might be air in the line. • If necessary, bleedthere the air in the lines. • Also check for fluid leakage around the fit• tings. end of the hose into a container.
34 PREPARATION Rear Shock Absorber Air Pressure Adjustment STD Air pressure: Atmospheric Rebound Damping Force Adjustment the position of the rebound damping • Check force adjuster at the upper end of each rear shock absorber. It has four positions. The numbers on the adjuster show the setting position. STD Rebound Damping Force: A. Tire Air Pressure Gauge No.
PREPARATION 35 NOTE żA permanent type of antifreeze is installed in the cooling system when shipped. It is colored 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 A. F (Full) Mark B. L (Low) Mark C. Right Side Cover NOTE żThis 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 drain plug tightness.
36 PREPARATION Final Gear Case Oil Final Gear Case Oil Level Inspection a helper hold the motorcycle vertical on • Have level ground. the filler cap. • Remove Check the If it is low, add oil as • necessary. oilThelevel. oil level should come to the bottom thread of the filler opening with the motorcycle held vertical on level ground. A. B. C. D.
PREPARATION 37 replacing the filler cap, be sure the O • When -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 kgf·m, 78 in·lb) A. Throttle Grip B. 2 ~ 3 mm (0.08 ~ 0.12 in.) the engine at idle speed, and turn the • Run handlebar all the way to the right and left to ensure that the idle speed does not change.
38 PREPARATION Headlight Aim The headlight beam is adjustable both horizontally and vertically. Headlight aim must be correctly adjusted for safe riding as well as oncoming drivers. In most areas it is illegal to ride with an improperly adjusted headlight. Horizontal Adjustment the horizontal adjusting screw on the • Turn headlight rim in or out until the beam points straight ahead. A.
PREPARATION 39 A. B. C. D. Rear Brake Light Switch Adjusting Nut Lights sooner. Lights later. CAUTION To avoid damaging the electrical connections inside the switch, be sure that the switch body does not turn during adjustment.
40 PREPARATION Fastener Check torque values listed are for assembly and • The 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 No.
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 dia. mm N·m Torque kgf·m 5 3.4~4.9 0.35~0.50 6 5.9~7.8 0.60~0.80 8 10 12 14 16 18 20 14~19 25~34 44~61 73~98 115~155 165~225 225~325 1.4~1.9 2.6~3.5 4.5~6.2 7.4~10.0 11.5~16.0 17.
MODEL APPLICATION Year Model 2005 VN1600–D1 Name VULCAN 1600 NOMAD VN1600 CLASSIC TOURER Part No.
