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Инструкция для KAWASAKI VN1600 CLASSIC (2003), VULCAN 1600 CLASSIC (2003)
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VULCAN 1600 CLASSIC
VN1600 CLASSIC
Motorcycle
Service Manual
Страница:
(
1
из 575)
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Оглавление инструкции
Document Outline
tables
LIST OF ABBREVIATIONS
Units of Mass:
Units of Volume:
Units of Force:
Units of Length:
Units of Torque:
Units of Pressure:
Units of Speed:
Units of Power:
Basic Torque for General Fasteners
Throttle Grip Free Play
Idle Speed
Water and Coolant Mixture Ratio (when shipping)
Engine Oil
Tread Depth
Air Pressure (when cold)
Final Gear Case Oil:
Pad Lining Thickness
Sample Diagnosis Sheet
Engine Doesn't Start, Starting Difficulty
Poor Running at Low Speed
Poor Running or No Power at High Speed:
Throttle Sensor Input Voltage
Idle Speed
Throttle Sensor Output Voltage
Throttle Sensor Resistance
Inlet Air Pressure Sensor Input Voltage
Inlet Air Pressure Sensor Output Voltage
Digital Volt Meter Connections
Inlet Air Temperature Sensor Output Voltage
Inlet Air Temperature Sensor Resistance
Water Temperature Sensor Output Voltage
Water Temperature Sensor Resistance
Atmospheric Pressure Sensor Input Voltage
Atmospheric Pressure Sensor Output Voltage
Vehicle-down Sensor Power Source Voltage
Vehicle-down Sensor Output Voltage
Injector Fuel Line Maximum Pressure
Injector Power Source Voltage at DFI Main Relay
Injector Output Voltage at ECU
Injector Wiring Inspection
Injector Resistance
Pump Operating Voltage at Pump
Pump Power Source Voltage
Pump Operating Voltage at Pump Connector
Ignition Coil Input Voltage at ECU
ECU Identification
ECU Grounding Inspection
ECU Power Source Inspection
Testing Relay
Power Source Voltage at ISC Valve Connector
Output Voltage of ISC Valves
ISC Valve Solenoid Resistance (##1, ##2)
Fuel Pressure
Fuel Pressure (idling)
Amount of Fuel Flow
Radiator Cap Relief Pressure
Thermostat Valve Opening Temperature
Vacuum Switch Valve Closing Pressure (Open → Close)
Camshaft/Rocker Case Clearance
Camshaft Journal Diameter
Cylinder Compression (Usable Range)
Cylinder Head Warp
Valve-to-Guide Clearance (Wobble Method)
Valve Seat Surface Outside Diameter (Seat O.D.)
Valve Seat Surface Width (or Seat Width)
[For Exhaust Valve Seat]
[For Inlet Valve Seat]
Cylinder Inside Diameter
Piston Diameter
Piston/Cylinder Clearance
Piston Ring/Groove Clearance
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
Spring Plate Gap
Steel Plates
Friction Plate Thickness
Friction or Steel Plate Warp
Clutch Spring Height
Oil Pressure
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing/Crankpin Clearance
Crankpin Diameter
Crankpin Diameter Marks
Connecting Rod Big End Inside Diameter Marks
Big End Bearing Insert Selection
Crankshaft Runout
Crankshaft Main Journal Diameter
Crankcase Main Bearing Bore Diameter
Crankshaft Side Clearance
Crankshaft Web Length
Shift Fork Ear Thickness
Gear Groove Width
Shift Fork Guide Pin Diameter
Shift Drum Groove Width
Rim Runout
Axle Runout/100 mm
Balance Weight
Preload for Pinion Gear Bearing
Shims for Preload Adjustment
Preload for Driven Gear Bearing
Front Bevel Gear Backlash (at the gear tooth)
Pedal Position
Front Disc Thickness
Rear Disk Thickness
Disc Runout
Front Fork Oil Level (Fully compressed without fork spring)
Spring Free Length
Rebound Damping Adjustment
Spring Preload Adjustment
Battery Terminal Voltage
Terminal Voltage: 11.5 ∼ less than 12.6 V
Terminal Voltage: less than 11.5 V
Battery Charging Voltage
Alternator Output Voltage
Stator Coil Resistance
Rectifier Circuit Inspection
3 Needle Arcing Distance
Ignition Coil Winding Resistance
Recommended Tool: Peak Voltage Adapter
Primary Lead Connections:
Ignition Coil Primary Peak Voltage
Recommended Tool: Peak Voltage Adapter
Connections:
Crankshaft Sensor Peak Voltage
Connections:
Ignition Timing
Connection:
Condition:
Interlock Operation Voltage
Condition:
Starter Motor Brush Length
Commutator Diameter
Testing Relay
Wiring Inspection
Connections
Testing Turn Signal Control Relay Inspection
Lighting Delay Time
Connections
Example:
Connections
Fuel Level Warning Indicator LED Light Connections:
Oil Pressure Warning Indicator LED Light Connections:
FI Indicator LED Light Connections:
Water Temperature Warning Indicator LED Light Connections:
Neutral Indicator Light Connections:
Neutral Indicator Light Connections:
High Beam Indicator Light Connections:
Fuel Level Sensor Resistance
Fan Switch Resistance
Water Temperature Switch Resistance
Fuse Circuit Inspection
Relay Circuit Inspection (with the battery disconnected)
Relay Circuit Inspection (with the battery connected)
Diode Circuit Inspection
toc
Read OWNER'S MANUAL before operating.
EMISSION CONTROL INFORMATION
1.
2.
3.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Foreword
General Information
Before starting to perform an inspection service or carry out a
Battery Ground
Edges of Parts
Solvent
Cleaning vehicle before disassembly
Arrangement and Cleaning of Removed Parts
Storage of Removed Parts
Inspection
Replacement Parts
Assembly Order
Tightening Sequence
Tightening Torque
Force
Gasket, O-ring
Liquid Gasket, Locking Agent
Press
Ball Bearing and Needle Bearing
Oil Seal, Grease Seal
Circlips, Cotter Pins
Lubrication
Direction of Engine Rotation
Electrical Wires
VN1600-A1 (US, and Canada) Left Side View:
VN1600-A1 (US, and Canada) Right Side View:
VN1600-A1 (Europe) Left Side View:
VN1600-A1 (Europe) Right Side View:
Prefixes for Units:
Units of Temperature:
Periodic Maintenance
The scheduled maintenance must be done in accordance with this c
The following tables list the tightening torque for the major fa
Steering Stem Nut Wrench :
Fuel System (DFI)
Fuel Hose and Connection Inspection
Throttle Control System Inspection
Idle Speed Inspection
Air Cleaner Element Cleaning
Torque -
Evaporative Emission Control System Inspection (CAL)
Cooling System
Radiator Hose and Connection Inspection
Torque -
Coolant Change
Torque -
Torque -
Engine Top End
Air Suction Valve Inspection
Clutch
Clutch Hose and Connection Inspection
Torque -
Clutch Fluid Level Inspection
Torque -
Clutch Fluid Change
Torque -
Clutch Master Cylinder Cup and Dust Seal Replacement
Special Tool -
Torque -
Clutch Slave Cylinder Piston Seal Replacement
Engine Lubrication System
Engine Oil Change
Torque -
Torque -
Special Tool -
Torque -
Oil Filter Replacement
Special Tool -
Torque -
Wheel/Tires
Tire Inspection
Final Drive
Oil Level Inspection
Special Tool -
Oil Change
Torque -
Propeller Shaft Joint Lubrication
Brakes
Brake Pad Wear Inspection
Brake Hose and Connection Inspection
Brake Fluid Level Inspection
Torque -
Brake Fluid Change
Torque -
Brake Master Cylinder Cup and Dust Seal Replacement
Caliper Piston/Dust Seals Replacement
Front Brake Light Switch Inspection
Rear Brake Light Switch Check/Adjustment
Suspension
Front Fork Oil Leak Inspection
Rear Shock Absorber Oil Leak Inspection
Swingarm Pivot Lubrication
Steering
Stem Bearing Lubrication
Steering Check
Special Tools -
Steering Adjustment
Special Tool -
Torque -
Torque -
Electrical System
Spark Plug Cleaning/Inspection
General Lubrication
Lubrication
Nut, Bolt, and Fastener Tightness
Tightness Inspection
Fuel System (DFI)
Terminal Numbers of ECU Connectors
Oil Pressure Gauge, 5 kgf/cm :
There are a number of important precautions that should be follo
Special Tool -
Torque -
Outline
Special Tool -
Special Tool -
DFI Diagnosis Flow Chart
Inquiries to Rider
NOTE
Self-diagnosis Procedures
Service Code Reading
Service Code Erasing
Footnotes:
Throttle Sensor Removal/Adjustment
Input Voltage Inspection
Special Tool -
Output Voltage Inspection
Special Tool -
Resistance Inspection
Removal
Installation
Input Voltage Inspection
Special Tool -
Output Voltage Inspection
Special Tools -
Pv = 24 ∼ 55 cm Hg
Pv = 55 ∼ 86 cm Hg
Removal/Installation
Torque -
Output Voltage Inspection
Special Tool -
Sensor Resistance Inspection
Removal/Installation
Torque -
Output Voltage Inspection
Special Tool -
Water Temperature Sensor Resistance Inspection
Removal
Installation
Input Voltage Inspection
Special Tool -
Output Voltage Inspection
Crankshaft Sensor ##1: for Front Cylinder (Service Code 21)
Crankshaft Sensor Removal/Installation
Crankshaft Sensor Inspection
Vehicle-down Sensor Removal
Installation
Vehicle-down Sensor Inspection
Special Tool -
Fuel Injector ##1: Front Fuel Injector for Front Cylinder (Servic
Injector Removal
Injector Installation
Torque -
Torque -
Audible Inspection
Power Source Voltage Inspection
Special Tool -
Output Voltage Inspection
Injector Signal Test
Special Tool -
Injector Resistance Inspection
Injector Unit Test
Fuel Pump Removal
Fuel Pump Installation
Torque -
Pressure Regulator Removal
Pump Screen, Fuel Filter Cleaning
Operation Inspection
Operating Voltage Inspection
Special Tools -
Power Source Voltage Inspection
Special Tool -
Operating Voltage Inspection
Ignition Coil ##1: Ignition Coil for Front Cylinder (Service Code
Removal/Installation
Input Voltage Inspection
Inspection Flow Chart
LED Light Inspection
ECU Identification
ECU Removal
ECU Installation
ECU Power Supply Inspection
Special Tool -
DFI Fuse Removal
DFI Fuse Inspection
DFI Main Relay Removal
DFI Main Relay Inspection
Special Tool -
DFI Power Source Circuit
Removal/Installation
Power Source Voltage Inspection
Output Voltage Inspection
Special Tool -
Resistance Inspection
Fuel Pressure Inspection
Special Tools -
Fuel Flow Rate Inspection
Throttle Grip Free Play Inspection
Throttle Grip Free Play Adjustment
Choke Knob Operation
Choke Cable Free Play Inspection
Cable Removal/Installation
Cable Lubrication and Inspection
Idle Speed Check
Idle Speed Adjustment
Throttle Bore Cleaning
High Altitude Performance Adjustment
Throttle Body Assy Removal
Throttle Assy Installation
Torque -
Non-permanent Locking Agent -
Torque -
Throttle Assy Disassembly/Assembly
Throttle Sensor [A]:
Throttle Stop Screw [A]:
Choke Lever Stop Screw [A]:
Throttle Cable Holder [B]:
Throttle Valve and Throttle Shaft:
Element Removal
Element Cleaning
Left Air Cleaner Housing Removal/Installation
Non-permanent Locking Agent -
Torque -
Right Air Cleaner Housing Removal
Right Air Cleaner Housing Installation
Non-permanent Locking Agent -
Torque -
Torque -
Torque -
Lower Air Cleaner Duct Removal/Installation
Torque -
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank and Cap Inspection
Fuel Tank Cleaning
The Evaporative Emission Control System for California Model rou
Parts Removal/Installation
Canister Installation
Canister Inspection (Periodic Inspection)
Separator Inspection (Periodic Inspection)
Hose Inspection (Periodic Inspection)
Separator Operation Test
Cooling System
Permanent type antifreeze is used as a coolant to protect the co
Bearing Driver Set :
Kawasaki Bond (Silicone Sealant) : 56019–120
Coolant Deterioration Inspection
Coolant Level Inspection
Coolant Draining
Coolant Filling
Pressure Testing
Cooling System Flushing
Water Pump Removal
Water Pump Installation
Torque -
Water Pump Inspection
Mechanical Seal Replacement
Special Tool -
Special Tools -
Special Tool -
Special Tool -
Special Tool -
Torque -
WARNING
Radiator Removal
Radiator Installation
Torque -
Radiator Inspection
Radiator Cap Inspection
Radiator Filler Neck Inspection
Thermostat Removal
Thermostat Installation
Thermostat Inspection
Hose Installation
Torque -
Hose Inspection
Engine Top End
Cam Height
Camshaft Journals and Runout
Valve Head Thickness
Valve Stem Bend
Valve Guide Reamer, 7 : 57001–162
Air Suction Valve Removal
Air Suction Valve Installation
Torque -
Air Suction Valve Check
Vacuum Switch Valve Removal
Vacuum Switch Valve Installation
Vacuum Switch Valve Operation Test
Vacuum Switch Valve Unit Test
Special Tool -
Clean Air System Hose Inspection
Camshaft Chain Tensioner Removal
Camshaft Chain Tensioner Installation
Torque -
Torque -
Torque -
Rocker Case Cover Removal
Rocker Case Cover Installation
Torque -
Rocker Case Cover Assembly
Rocker Case Removal
Special Tool -
Rocker Case Installation
Torque -
Sealant -
Torque -
Torque -
Torque -
Torque -
Rocker Arm Assembly
HLA Removal
HLA Air Bleeding
HLA Installation
Camshaft Removal
Special Tool -
Camshaft Installation
Torque -
Camshaft Sprocket Installation
Torque -
Camshaft/Rocker Case Wear
Torque -
Front Camshaft Chain Removal
Special Tool -
Rear Camshaft Chain Removal
KACR Inspection
Cylinder Compression Measurement
Special Tool -
Special Tools -
Torque -
Cylinder Head Removal
Special Tool -
Cylinder Head Installation
Special Tool -
Torque -
Torque -
Cylinder Head Warp
Valve Clearance Adjustment
Valve Removal
Special Tools -
Valve Installation
Valve Guide Removal
Special Tool -
Valve Guide Installation
Special Tool -
Special Tool -
Valve Guide Wear (Wobble Method)
Valve Seat Inspection
Valve Seat Repair
Special Tools -
Cylinder Removal
Piston Removal
Special Tools -
Cylinder, Piston Installation
Special Tools -
Cylinder Wear
Piston Wear
Piston/Cylinder Clearance
Cylinder Boring and Honing
Piston Ring, Piston Ring Groove Wear
Piston Ring Groove Width
Piston Ring Thickness
Piston Ring End Gap
Exhaust Pipe Removal (For other than U.S.A. and Canadian Models)
Lower Muffler Removal (For other than U.S.A. and Canadian Models
Upper Muffler Removal (For other than U.S.A. and Canadian Models
Muffler, Exhaust Pipe Installation (For other than U.S.A. and Ca
Torque -
Torque -
Chamber Removal (For other than U.S.A. and Canadian Models)
Chamber Installation (For other than U.S.A. and Canadian Models)
Torque -
Chamber Assembly (For other than U.S.A. and Canadian Models)
Chamber Identification (For other than U.S.A. and Canadian Model
Front Exhaust Pipe Removal (U.S.A. and Canadian Models)
Rear Exhaust Pipe Removal (U.S.A. and Canadian Models)
Muffler Removal (U.S.A. and Canadian Models)
Muffler, Exhaust Pipe Installation (U.S.A. and Canadian Models)
Torque -
Torque -
Clutch
Inside Circlip Pliers :
Clutch Fluid Level Check
Clutch Fluid Change
Clutch Line Bleeding
Torque -
Clutch Hose Removal/Installation
Clutch Hose and Connection Check
Clutch Lever Adjustment
Clutch Master Cylinder Removal
Clutch Master Cylinder Installation
Torque -
Torque -
Clutch Master Cylinder Disassembly/Assembly
Clutch Master Cylinder Inspection
Clutch Slave Cylinder Removal
Clutch Slave Cylinder Installation
Torque -
Torque -
Clutch Slave Cylinder Disassembly/Assembly
Clutch Cover Removal
Special Tools -
Clutch Removal
Clutch Installation
Torque -
Special Tool -
Inner Clutch Hub Disassembly
Special Tool -
Spring Plate Gap Measurement
Spring Plate Gap Adjustment
Friction and Steel Plate Wear, and Damage Inspection
Friction or Steel Plate Warp
Clutch Spring Height Measurement
Clutch Housing Finger Inspection
Outer Clutch Hub Spline Inspection
Cam Damper Inspection
Engine Lubrication System
Oil Pressure Gauge, 5 kgf/cm :
WARNING
Oil Level Inspection
Engine Oil Change
Oil Filter Replacement
Oil Pump Removal
Oil Pump Installation
Torque -
Torque -
Oil Hose Removal
Oil Hose Installation
Torque -
Torque -
Inside Oil Pipe Removal
Inside Oil Pipe Installation
Torque -
Torque -
Blowby Gas System Inspection
Breather Drain Cleaning
Oil Pressure Measurement
Special Tools -
Torque -
Relief Valve Inspection
Engine Removal/Installation
Jack : 57001–1238
Attachment Jack : 57001–1398
Engine Removal
Special Tools -
Engine Installation
Torque -
Torque -
Crankshaft/Transmission
Outside Circlip Pliers :
Crankcase Disassembly
Special Tool -
Special Tool -
Special Tool -
Special Tool -
Crankcase Assembly
Special Tool -
Special Tool -
Torque -
Torque -
Sealant -
Torque -
Torque -
Sealant -
Torque -
Torque -
Torque -
Special Tool -
Torque -
Torque -
Torque -
Torque -
Starter Clutch Disassembly
Special Tool -
Starter Clutch Assembly
Torque -
Special Tool -
Starter Clutch Inspection
Starter Torque Limiter Check
Connecting Rod Removal
Connecting Rod Installation
Torque -
Crankshaft/Connecting Rod Cleaning
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side Clearance
Connecting Rod Big End Bearing Wear
Torque -
Molybdenum Disulfide Oil -
Torque -
Crankshaft Runout
Crankshaft Main Bearing/Journal Wear
Crankshaft Side Clearance
Primary Gear Removal
Special Tool -
Primary Gear Installation
Torque -
Special Tool -
Torque -
Shift Pedal Removal
Shift Pedal Installation
Torque -
Torque -
External Shift Mechanism Removal
External Shift Mechanism Installation
Torque -
Torque -
External Shift Mechanism Inspection
Torque -
Transmission Removal
Transmission Installation
Torque -
Shift Drum Disassembly/Assembly
Torque -
Transmission Disassembly
Special Tool -
Transmission Assembly
Shift Fork Bending
Shift Fork/Gear Groove Wear
Shift Fork Guide Pin/Drum Groove Wear
Gear Dog and Gear Dog Hole Damage
Ball Bearing and Outer Race Replacement
Special Tool -
Ball and Needle Bearing Wear
Oil Seal Inspection
Wheels/Tires
Inside Circlip Pliers :
Front Wheel Removal
Special Tools -
Front Wheel Installation
Torque -
Torque -
Torque -
Rear Wheel Removal
Special Tools -
Rear Wheel Installation
Torque -
Wheel Coupling Removal
Wheel Coupling Installation
Wheel Inspection
Special Tools -
Axle Inspection
Wheel Balance
Balance Inspection
Balance Adjustment
Balance Weight Removal
Balance Weight Installation
Air Pressure Inspection/Adjustment
Tire Inspection
Tire Removal
Tire Installation
Torque -
Torque -
Tire Repair
Hub Bearings Removal
Special Tool -
Special Tools -
Hub Bearings Installation
Special Tool -
Special Tool -
Special Tool -
Hub Bearings Inspection
Hub Bearings Lubrication
Final Drive
Bearing Puller :
Oil Level Inspection
Oil Change
Final Gear Case Removal
Final Gear Case Installation
Torque -
Final Gear Case Disassembly
Special Tool -
Special Tool -
Final Gear Case
Final Gear Case Assembly
Special Tool -
Special Tool -
Torque -
Torque -
Pinion Gear Removal
Special Tool -
Special Tool -
Special Tool -
Pinion Gear Installation
Special Tool -
Special Tool -
Special Tool -
Torque -
Special Tool -
Pinion Gear Bearing Preload Adjustment
Special Tool -
Bevel Gear Inspection
Pinion Gear Joint Inspection
Final Bevel Gear Adjustment
Backlash-Related Parts
Backlash Adjustment
Special Tool -
Torque -
Torque -
Tooth Contact Adjustment
Special Tool -
Torque -
Correct Tooth Contact Pattern: No adjustment is required.
Incorrect Tooth Contact Patterns (Example 1)
Incorrect Tooth Contact Patterns (Example 2)
Propeller Shaft Removal
Propeller Shaft Installation
Propeller Shaft Joint Lubrication
Propeller Shaft Inspection
Sliding Joint Inspection
Front Gear Case Removal
Front Gear Case Installation
Torque -
Front Gear Case Disassembly
Special Tool -
Special Tool -
Front Gear Case Assembly
Special Tool -
Non-permanent Locking Agent -
Torque -
Torque -
Torque -
Torque -
Driven Gear Disassembly
Special Tool -
Special Tools -
Driven Gear Assembly
Special Tool -
Special Tool -
Torque -
Damper Cam Removal
Special Tool -
Damper Cam Installation
Torque -
Special Tool -
Front Bevel Gear Adjustment
Front Bevel Gear Adjustment
Preload Adjustment
Torque -
Preload Measurement with Spring Scale
Special Tool -
Bearing Preloading Mechanism
Backlash Adjustment
Torque -
Torque -
Tooth Contact Adjustment
Bevel Gear Inspection
Cam Damper Inspection
Ball or Needle Bearing Replacement
Special Tools -
Special Tool -
Special Tool -
Ball Bearing Wear
Tapered Roller Bearing Inspection
Needle Bearing Inspection
Oil Seal Inspection
Brakes
Inside Circlip Pliers :
Brake Lever Position Adjustment
Brake Pedal Position Adjustment
Torque -
Brake Pedal Removal
Brake Pedal Installation
Torque -
Front Caliper Removal
Rear Caliper Removal
Caliper Installation
Torque -
Front Caliper Disassembly
Front Caliper Assembly
Torque -
Rear Caliper Disassembly
Rear Caliper Assembly
Torque -
Caliper Fluid Seal Damage
Caliper Dust Boot and Friction Boot Damage
Caliper Piston and Cylinder Damage
Caliper Holder Shaft Wear
Front Brake Pad Removal
Front Brake Pad Installation
Rear Brake Pad Removal
Rear Brake Pad Installation
Brake Pad Wear Inspection
Front Master Cylinder Removal
Front Master Cylinder Installation
Torque -
Torque -
Rear Master Cylinder Removal
Rear Master Cylinder Installation
Torque -
Front Master Cylinder Disassembly
Special Tool -
Rear Master Cylinder Disassembly
Special Tool -
Master Cylinder Assembly
Silicone Grease -
Torque -
Master Cylinder Inspection
Brake Disc Removal
Brake Disc Installation
Torque -
Brake Disc Wear
Brake Disc Warp
Brake Fluid Level Inspection
Brake Fluid Change
Brake Line Bleeding
Torque -
Brake Hose Removal/Installation
Torque -
Suspension
Fork Cylinder Holder Handle :
Fork Oil Change
Special Tool -
Torque -
Front Fork Removal
Special Tools -
Front Fork Installation
Torque -
Torque -
Torque -
Disassembly
Special Tools -
Special Tool -
Assembly
Special Tool -
Special Tool -
Special Tools -
Torque -
Inner Tube, Outer Tube Inspection
Dust Seal Inspection
Spring Tension
Rebound Damping Adjustment
Spring Preload Adjustment
Rear Shock Absorber Removal
Special Tools -
Rear Shock Absorber Installation
Torque -
Rear Shock Absorber Inspection
Swingarm Removal
Special Tools -
Swingarm Installation
Torque -
Torque -
Swingarm Bearing Removal
Special Tool -
Swingarm Bearing Installation
Special Tool -
Swingarm Bearing, Sleeve Inspection
Grease Seal and Needle Bearing Lubrication
Steering
Head Pipe Outer Race Press Shaft :
Handlebar Removal
Handlebar Installation
Torque -
Steering Check
Steering Adjustment
Steering Stem Removal
Special Tools -
Steering Stem Installation
Torque -
Torque -
Steering Stem Warp
Stem Bearing Removal
Special Tool -
Stem Bearing Installation
Special Tools -
Special Tools -
Special Tool -
Torque -
Stem Bearing Lubrication
Stem Cap Deterioration, Damage
Frame
Jack :
Rear Seat Removal
Rear Seat Installation
Front Seat Removal
Front Seat Installation
Left Side Cover Removal
Left Side Cover Installation
Right Side Cover Removal/Installation
Front Fender Removal
Rear Fender Removal
Battery Case Removal
Tool Box Removal
Footboard Removal
Footboard Disassembly
Sidestand Installation
Torque -
Downtube Removal
Special Tools -
Downtube Installation
Torque -
Frame Inspection
Electrical System
Spark Plug Wrench, Hex 18 :
Left Handlebar Switches [A]
There are a number of important precautions that should be follo
Wiring Inspection
Special Tool -
Battery Removal
Battery Installation
Electrolyte Filling
Initial Charge
Precautions
1)
2)
3)
4)
Interchange
Charging Condition Inspection
Refreshing Charge
Alternator Outer Cover Removal
Alternator Outer Cover Installation
Torque -
Alternator Cover Removal/Installation
Sealant -
Torque -
Alternator Cover Assembly
Alternator Inner Cover Removal
Special Tools -
Alternator Inner Cover Installation
Torque -
Torque -
Alternator Rotor Removal
Special Tool -
Alternator Rotor Installation
Torque -
Alternator Outside Stator Removal
Alternator Outside Stator Installation
Non-permanent Locking Agent -
Torque -
Torque -
Non-permanent Locking Agent -
Torque -
Alternator Inside Stator Removal
Alternator Inside Stator Installation
Non-permanent Locking Agent -
Torque -
Charging Voltage Inspection
Special Tool -
Alternator Inspection
Special Tool -
Regulator/Rectifier Removal
Regulator/Rectifier Installation
Torque -
Rectifier Inspection
Regulator Inspection
Charging System Circuit
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Special Tool -
Spark Plug Removal
Special Tool -
Spark Plug Installation
Special Tool -
Torque -
Spark Plug Cleaning/Inspection
Ignition Coil Primary Peak Voltage
Special Tool -
Crankshaft Sensor Removal
Crankshaft Sensor Installation
Crankshaft Sensor Inspection
Special Tool -
Ignition Timing Inspection
Special Tool -
Special Tool -
Interlock Operation Inspection
IC Igniter Inspection
Ignition System Circuit
Starter Motor Removal
Starter Motor Installation
Torque -
Starter Motor Disassembly
Starter Motor Assembly
Torque -
Brush Inspection
Commutator Cleaning and Inspection
Armature Inspection
Special Tool -
Brush Assy Inspection
Brush Plate and Terminal Bolt Inspection
Starter Relay Inspection
Electric Starter Circuit
This model adopts the daylight system and has a headlight relay
Headlight Beam Horizontal Adjustment
Headlight Beam Vertical Adjustment
Headlight Bulb Replacement
Torque -
Headlight Body Removal
City Light Bulb Replacement (other than US, CA and AU)
Tail/Brake Light Bulb Replacement
Torque -
Headlight/Tail Light Circuit
Automobiles use a turn signal canceling system actuated by steer
Wiring Inspection
Special Tool -
Distance Sensor Inspection
Special Tools -
Turn Signal Switch Inspection
Turn Signal Switch Connections
Turn Signal Control Relay Inspection
Turn Signal Light Bulb Replacement
Torque -
Turn Signal Cancelling System Circuit
WARNING
Fan System Circuit Inspection
Fan Motor Inspection
Radiator Fan Circuit
Motorcycle operation with low engine oil level, even if it is hi
Oil Pressure Warning System Circuit
Oil Pressure Light Delay Unit Removal
Oil Pressure Light Delay Unit Inspection
Meter Unit Removal
Meter Unit Installation
Meter Unit Disassembly
Meter Unit Assembly
Meter Unit Inspection
Special Tools -
Special Tool -
LED Light Inspection
Indicator Light Inspection
Meter Unit Circuit
Water Temperature Warning System Check
Fuel Level Sensor Inspection
Special Tool -
Torque -
Fuel Reserve Switch Inspection
Speed Sensor Removal
Speed Sensor Installation
Non-permanent Locking Agent -
Torque -
Speed Sensor Inspection
Special Tool -
Front Brake Light Switch Inspection
Rear Brake Light Switch Check/Adjustment
Radiator Fan Switch Removal
Radiator Fan Switch Installation
Torque -
Radiator Fan Switch Inspection
Water Temperature Switch Removal
Water Temperature Switch Installation
Sealant -
Torque -
Water Temperature Switch Inspection
Switch Inspection
Special Tool -
Rear Brake Light Switch Connections
Side Stand Switch Connections
Neutral Switch Connections
Oil Pressure Switch Connections*
The junction box [A] has fuses [B], relays, and diodes. The rela
Junction Box Fuse Circuit Inspection
Starter Circuit/Headlight Relay Inspection
Diode Circuit Inspection
Junction Box Internal Circuit
Main Fuse Removal
Junction Box Fuse Removal
Fuse Installation
Fuse Inspection
Appendix
NOTE
Engine Doesn't Start, Starting Difficulty:
Starter motor not rotating:
Starter motor rotating but engine doesn't turn over:
Engine won't turn over:
No fuel flow:
Engine flooded:
No spark; spark weak:
Fuel/air mixture incorrect:
Compression Low:
Poor Running at Low Speed:
Spark weak:
Fuel/air mixture incorrect:
Compression low:
Backfiring when deceleration:
Other:
Poor Running or No Power at High Speed:
Firing incorrect:
Fuel/air mixture incorrect:
Compression low:
Knocking:
Miscellaneous:
Overheating:
Firing incorrect:
Muffler overheating:
Fuel/air mixture incorrect:
Compression high:
Engine load faulty:
Lubrication inadequate:
Water temperature warning system incorrect:
Coolant incorrect:
Cooling system component incorrect:
Over Cooling:
Cooling system component incorrect:
Clutch Operation Faulty:
Clutch slipping:
Clutch not disengaging properly:
Gear Shifting Faulty:
Doesn't go into gear; shift pedal doesn't return:
Jumps out of gear:
Overshifts:
Abnormal Engine Noise:
Knocking:
Piston slap:
Valve noise:
Other noise:
Abnormal Drive Train Noise:
Clutch noise:
Transmission noise:
Drive line noise:
Abnormal Frame Noise:
Front fork noise:
Rear shock absorber noise:
Disc brake noise:
Other noise:
Oil Pressure Warning Light Goes On:
Exhaust Smokes Excessively:
White smoke:
Black smoke:
Brown smoke:
Handling and/or Stability Unsatisfactory:
Handlebar hard to turn:
Handlebar shakes or excessively vibrates:
Handlebar pulls to one side:
Shock absorption unsatisfactory:
Brake Doesn't Hold:
Battery Trouble:
Battery discharged:
Battery overcharged:
Инструкции и руководства похожие на KAWASAKI VN1600 CLASSIC (2003), VULCAN 1600 CLASSIC (2003)
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KAWASAKI NINJA ZX-6R (2000-2002)
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