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Kawasaki Vulcan Classic FI Service Manual
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Kawasaki vulcan 1500 classic service manual download
Clevis 4. Brake Hose White Marks Position here. Rear Brake Reservoir Cover 5. Clamps Fuel Return Hose 2. Fuel Tank Breather Hose 3. Separator Breather Hose 4. Canister Purge Hose 5. Fuel Tank Filler 2.
Fuel Tank Breather Pipe 4. Filler Drain Pipe 5. Fuel Tank 6. Separator 7. Canister 8. Clips for [13] and [15] 9. Fuel Tank 2. Left Air Cleaner Base 3. Canister CAL 5. Fuel Breather Hose right, blue 6. Rear View 7. Ignition Coils 4. Ignition Switch 5. Starter Motor 6. Water Temperature Switch 7. Pickup Coils 9. Alternator Sidestand Switch Ignition Coils see preceding page 4. Ignition Switch see preceding page 5. Starter Motor see preceding page 6. Water Temperature Switch see preceding page 7.
Throttle Cable accelerator 2. Throttle Cable decelerator 3. Choke Cable 4. In-tank Fuel Filter 5. To vacuum sensor 6. Atmospheric Pressure Sensor 7. Vacuum Sensor 8. Fuel Pump Gasket 9.
In-tank Fuel Pump electric Page 83 T3: 2. SS: Apply silicone sealant Kawasaki Bond: Pickup Coil 1 3. Pickup Coil 2 4. Pressure Regulator 5. Throttle Sensor front view 6. Engine Stop Switch 1. Do not use any other battery except for a 12 V battery as a power source. Be sure to install the oil filler cap [A] after filling the engine oil, using the filler cap driver [B].
If the free play is incorrect, adjust the throttle cable. The DFI system has an automatic choke system, using ISC valves, a water temperature sensor, and an atmo- spheric pressure sensor, which provide startability. Page High Altitude Performance Adjustment Any modification is not necessary in this model since the atmospheric pressure sensor senses atmospheric pres- sure change due to high altitude and the ECU compen- sates the change. Tampering with the screw could cause malfunction of the choke lever.
These nuts and lower air cleaner duct are sold as a unit. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Part No. If the dampers are damaged or deteriorated, replace them.
Replace the gasket if it is damaged. Although no adjustments are required, a thorough visual inspection must be made at the intervals specified by the Periodic Maintenance Chart. If the separator has any cracks or damage, replace it with a new one. In addition, the condition of the problem is stored in the memory of the ECU electronic control unit. Page After measurement, remove the needle adapters and ap- ply silicone sealant to the seals [A] of the connector [B] for waterproofing.
A fully charged battery is a must for conducting accurate tests of the DFI system. This enables to check a long harness for continuity. Inspection starts. This can be identified by engine sound or vibration. J : Knock A periodic, rattling, thumping or pounding noise caused by spontaneous ignition of the air-fuel mixture in a cylinder, leading to engine damage. Year of initial registration Model Engine No. Frame No. Date problem occured Mileage Environment when problem occurred.
Such a shock to the ECU can damage it. If necessary, disconnect the ECU connectors. If the connector is clogged with mud or dust, blow it off with compressed air. Replace the main harness if the terminals of the main harness connectors are cracked, bent, or otherwise dam- aged. When the engine is cold, each ISC valve is opened according to the coolant temperature by the ECU, providing good starta- bility in cold weather and allowing the engine to run fast for quick warm up fast idle.
Such a shock to the valve can damage it. This circuit includes parts [D], and wiring [E]. But even if the repair has been done, the ignition switch is turned OFF, or the battery is disconnected, all the fault codes remain in the ECU, which need not be absolutely eraced. This method is called D-J method. As engine speed increases, and the en- gine load turns middle to heavy, the ECU determines injection quantity by calculating from throttle opening throttle sensor output voltage and engine speed.
The ECU senses this voltage change and determines fuel injection quantity, and ignition timing according to engine rpm, and throttle opening. Page If the reading is out of the standard range, inspect the throttle sensor resistance. Silicone Sealant- Kawasaki Bond: Such a shock to the part can damage it.
Page Output Voltage Inspection Turn the ignition switch OFF, remove the needle adapters and apply silicone sealant to the seals of the sensor con- nector for waterproofing. Page If the output voltage is out of the usable range, replace the sensor. Silicone Sealant- Kawasaki Bond: If the wiring is good, check the sensor resistance.
Page If the wiring is good, check the water temperature sensor resistance. Such a shock to the sensor can damage it. Page Output Voltage Inspection Remove the needle adapters. Note the following. If you know the local atmospheric pressure using a barometer, substitude the atmospheric pressure for Pv Throttle Vacuum in the vacuum sensor chart see Vac- uum Sensor section in this chapter.
Page Remove the needle adapters, and apply silicone sealant to the seals of the vehicle-down sensor connector for wa- terproofing. Silicone Sealant- Kawasaki Bond: If the output voltage is normal, the wiring is suspect. Check the wiring. If the wiring is good, check the ECU for its ground and power supply see this chapter. Such a shock to the pump can damage it. If the fuel filter is suspected of clogging or being damaged, replace it with the fuel pump as a set.
Coolant Flow Chart Coolant Deterioration Inspection Coolant Level Inspection Coolant Draining Coolant Filling Pressure Testing G: Apply grease. When the engine starts, the water pump turns and the coolant circulates. The thermostat is a wax pellet type which opens or closes as coolant temperature changes.
The thermostat continuously changes its valve opening to keep the coolant temperature at the proper level. Water Pump 2. Water Jacket 3. Cylinder Head 4. Water Pipe 5. Water Hose 6. Radiator Cap 7. Thermostat 8. Reserve Tank Hose 9. Radiator Radiator Fan Throttle Assy Front If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting.
First turn the cap counterclockwise to the first stop. Torque – Radiator Drain Bolt: 7. When this accumulation is suspected or observed, flush the cool- ing system. If this accumulation is not removed, it will clog up the water passage and considerably reduce the effi- ciency of the cooling system. If the mechanical seal is damaged, the coolant leaks through the seal and drain through the passage. Replace the mechanical seal.
The radiator fan may start even if the ignition switch is off. If there are obstructions to air flow, remove them. If the corrugated fins [A] are deformed, carefully straighten them. They must be smooth and clean for the radiator cap to function properly.
Page Muffler, Exhaust Pipe Installation. Page Exploded View 10 : 1 T5: 7. Rear Exhaust Pipe T2: 6. Front Exhaust Pipe M: Apply molybdenum disulfide grease. Upper Muffler PN: Spray a penetrating oil on the nuts and 4. Lower Muffler studs if the nuts are difficult to remove. L: Apply a non-permanent locking agent. MO: Apply molybdenum disulfide oil. Sealant – Kawasaki Bond Silicone Sealant : When the vacuum is low, the vacuum switch valve should permit air to flow. When the vacuum raises to valve closing pressure, it should stop air flow.
The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. Torque – Chain Tensioner Mounting Bolts: 9. Do not con- fuse the springs. Camshaft Journal Diameter 25 There are only two symptoms of prob- lems with the KACR mechanism [A]; compression is not re- leased during starting, and compression is released during running.
Do not remove the other spark plug, only the plug lead. Be careful not to mix them up. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. Be careful not to mix up these chain guides since the front chain guide for the rear cylinder is longer. If the measurement is under service limit, replace the pis- ton. The rings should fit perfectly parallel to groove surfaces.
If not, replace the piston and all the piston rings. Set it close to the bottom of the cylinder, where cylinder wear is low. Wait until the muffler cools down. Clutch Lever Position Adjustment Clutch Fluid Fluid Level Inspection Clutch Fluid Changing Clutch Line Bleeding Clutch Master Cylinder Clutch Master Cylinder Removal Clutch Master Cylinder Installation Clutch Master Cylinder Disassembly Clutch Slave Cylinder T 6.
Cup point side faces outside. EO: Apply engine oil. If the fluid level is lower than the lower level line, fill the reservoir to the upper level line in the reservoir. If necessary, bleed the air from the lines see Clutch Line Bleeding. If the master cylinder or piston shows any damage, re- place them. It may damage painted surfaces. Torque – Clutch Slave Cylinder Bolts: 6. Clutch Installation When replacing any one of the following parts, check the spring plate free play see Spring Plate Free Play Mea- surement.
Spring Plate Gap Usable Range: 1. Replace any damaged parts. Exploded View Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Oil Filter Change Oil Screen Cleaning Oil Pump Oil Screen 2. Oil Pump 3. Relief Valve 4. Oil Filter 5. Bypass Valve 6. Oil Pressure Switch 7. Inside Oil Pipe 8.
Banjo Bolts of Right Crankcase Rear 9. Outside Oil Hoses Page Exploded View L: Apply a non-permanent locking agent. Engine Removal Engine Installation Primary Gear LG: Apply liquid gasket Kawasaki Bond: The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 : 1. Each bolt head is numbered Align the punch marks. Align the punch mark with the slit. T1: 9. Drive Shaft 2. Page 0. Crankpin Diameter Standard: Service Limit: If the crankpin has worn past the service limit, replace the crankshaft with a new one.
If the measurement exceeds the service limit, replace the crankshaft. Service Limit: TIR 0. The torque limiter will be damaged. If it is loose, unscrew it, apply a non-permanent locking agent to the threads, and tighten it.
Bushing 5th Gear 2. Needle Bearing 8. Washer Output Shaft 7. Bushing 3rd Gear 2. Steel Balls 3. Output Shaft 8. Steel Balls 2. If the guide pin on any shift fork is less than the service limit, the fork must be replaced. Removal may damage them. Replace it if the lips are misshapen, discolored indicating that the rubber has deteriorated , hardened or otherwise damaged. Wheels Rims Front Wheel Removal Front Wheel Installation Rear Wheel Removal Rear Wheel Installation Wheel Coupling Removal Wheel Coupling Installation Wheel Inspection Spoke Tightness Inspection Rim Inspection R: Replacement Parts S: Follow the specific tightening sequence.
If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque – Spoke Nipples: 2. If the axle is damaged or bent, replace it. An imbalance of less than 10 grams 0. Adjust the tire air pressure if necessary. If the rim flanges and tire sidewall bead lines are not par- allel, remove the valve core.
Spring Pin L: Apply a non-permanent locking agent. Be careful not to scratch the sealing surface on the ring gear hub. Pinion Gear Nut 2. Washer 3. Pinion Gear Joint 4. O-ring 5. Ring Gear Hub 6. Ring Gear Oil Seal 7. Ball Bearing 8. Final Gear Case Cover 9. Pinion Gear Nut Pinion Gear Shim s 2. O-ring 3. Shim s for Preload Oil Seal 4. Pinion Gear Joint No two are alike. Each Kawasaki product line has a distinct VIN location.
The exact location for these numbers in your particular model is illustrated in your owner’s manual near the front of the book. They also appear on your registration documents. The Vehicle Category field is required. Select a Year. The Vehicle Model field is required.
Select Vehicle. HINs have 12 digits. They look like this: KAWJ Motorcycles You will find the VIN stamped on the steering head, below the handlebars. Mule Utility Vehicles You will find the VIN on the top edge of the front bench seat base, just below the seat cushion.
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Kawasaki VULCAN , VN Classic Fi Motorcycle PDF
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Electronic guide covers safety requirements, operation, maintenance, service, system information, testing and adjusting section, disassembly and assembly. Slipping overrunning clutch assembly. The accelerator pump circuit reduces engine hesitation by injecting a fine spray of fuel into the carburetor intake passage during sudden acceleration. Refer to Figure 1.
