User manual KAWASAKI VN 1600 CLASSIC SERVICE MANUAL

[. . . ] VULCAN 1600 CLASSIC VN1600 CLASSIC Motorcycle Service Manual Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System This quick reference guide will assist you in locating a desired topic or pro cedure. ·Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page. ·Refer to the sectional table of contents for the exact pages to locate the spe cific topic required. 1j 2j 3j 4j 5j 6j 7j 8j 9j 10 j 11 j 12 j 13 j 14 j 15 j 16 j Appendix 17 j VULCAN 1600 CLASSIC VN1600 CLASSIC Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd. , Japan. [. . . ] up the engine, wait until · Thoroughly warmretighten all the clamp bolts. the engine cools down, and Torque - Muffler Bracket Bolt and Nut: 29 N·m (3. 0 kgf·m, 22 ft·lb) Torque - Exhaust Pipe Cover Clamp Screws: 6. 9 N·m (0. 70 kgf·m, 61 in·lb) CLUTCH 6-1 Clutch Table of Contents Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools and Sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Fluid Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Line Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Hose Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Hose and Connection Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Lever Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Master Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Master Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Master Cylinder Disassembly/Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Master Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Slave Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Slave Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Slave Cylinder Disassembly/Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inner Clutch Hub Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6-4 6-5 6-6 6-6 6-6 6-6 6-6 6-6 6-7 6-7 6-7 6-7 6-7 6-8 6-9 6-9 6-9 6-10 6-11 6-11 6-11 6-13 6-14 6-14 6-16 6-16 6-16 6-17 6-17 6-17 6-17 6 6-2 CLUTCH Exploded View CLUTCH 6-3 Exploded View No. 1 2 3 4 5 6 7 8 9 Fastener Clutch reservoir cap screws Clutch slave cylinder bleed valve Clutch master cylinder clamp bolts Clutch hose banjo bolt Clutch slave cylinder bolts Clutch pipe banjo bolt Clutch hub nut Clutch cover bolts Clutch damper cover bolts Torque N·m 1. 5 7. 8 11 25 6. 9 25 147 11 9. 8 4. 9 1. 0 5. 9 1. 2 9. 8 kgf·m 0. 15 0. 80 1. 1 2. 5 0. 70 2. 5 15. 0 1. 1 1. 0 0. 50 0. 10 0. 60 0. 12 1. 0 ft·lb 13 in·lb 69 in·lb 95 in·lb 18 61 in·lb 18 108 95 in·lb 87 in·lb 43 in·lb 8. 7 in·lb 52 in·lb 10 in·lb 87 in·lb EO L L Si L S Remarks 10 Clutch damper screws 11 Clutch lever pivot bolt 12 Clutch lever pivot bolt locknut 13 Starter lockout switch screw 14 Clutch damper plate bolts 15. Si: Apply silicone grease or PBC grease. 6-4 CLUTCH Specifications Item Clutch Fluid Grade Clutch Lever Position Clutch Lever Free Play Clutch Clutch spring free height Spring plate gap (usable range) Friction plate thickness Friction or steel plate warp Standard DOT4 (provided when shipping) No. 1 (to suit rider) Non-adjustable 4. 3 mm (0. 235 in) 1. 95 2. 45 mm (0. 0768 0. 0965 in) 3. 3 3. 5 mm (0. 130 0. 138 in) 0. 2 mm (0. 0079 in) or less Service Limit ­­­ 5-way adjustable ­­­ 4. 0 mm (0. 16 in) ­­­ 3. 1 mm (0. 122 in) 0. 3 mm (0. 012 in) CLUTCH 6-5 Special Tools and Sealant Inside Circlip Pliers : 57001­143 Gear Holder, m2. 0 : 57001­1557 Clutch Spring Compressor : 57001­1162 6-6 CLUTCH Clutch Fluid Clutch Fluid Level Check nance Chapter. Refer to Clutch Fluid Level Check in the Periodic Mainte Clutch Fluid Change Chapter. Refer to Clutch Fluid Change in the Periodic Maintenance Clutch Line Bleeding · Remove: Outer Cover (see Electrical System chapter) Alternator 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 reser voir. This bleeds the air from the master cylinder end of the line. Tap the clutch hose lightly going from the lower end to the upper end and bleed the air off at the reservoir. a clear plastic hose [A] to · Attach slave cylinder, and run the the bleed valve on the clutch other end of the hose into a container. NOTE · Bleed the clutch line asafollows: until it becomes hard Pump the clutch lever few times and then hold it applied [B]. Quickly open and close [C] the bleed valve. Release [D] the clutch lever. Check the fluid level in the reservoir often, replenishing it as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have en tered the line. NOTE Repeat this operation until no more air can be seen com ing out into the plastic hose. WARNING Do not mix different grades and brands of fluid. Torque - Clutch Reservoir Cap Screws: 1. 5 N·m (0. 15 kgf·m, 13 in·lb) Clutch Slave Cylinder Bleed Valve: 7. 8 N·m (0. 80 kgf·m, 69 in·lb) Clutch Hose Removal/Installation Since the clutch hose is the same as the brake hose, refer to Brake Hoses section in the Brakes chapter for clutch hose removal or installation. Clutch Hose and Connection Check odic Maintenance Chapter. Refer to Clutch Hose and Connection Check in the Peri CLUTCH 6-7 Clutch Master Cylinder Clutch Lever Adjustment The adjuster has 5 positions so that the clutch lever posi tion can be adjusted to suit the operator's hand. Push the lever forward and turn the adjuster [A] to align the number with the arrow mark [B] on the lever holder (front view). The distance from the grip to the lever is minimum at num ber 5 and maximum at number 1. · Clutch Master Cylinder Removal switch connector [A]. · Disconnect the starter lockout the reservoir with a means Draw out the clutch fluid from · like the fork oil level gauge. the banjo bolt · Remove master cylinder[A] to disconnect the clutch hose from the (rear view). Unscrew the clamp bolts [B], and take off the master cylin· der [C] as an assembly with the clutch reservoir, clutch lever, and starter lockout switch installed. CAUTION Clutch fluid quickly ruins painted surface; any spilled fluid should be completely washed away immediately. Clutch Master Cylinder Installation The master cylinder clamp must be installed with the rear · · view mirror boss [A] upward. Set the clutch master cylinder [B] to match its mating surface [C] to the punch mark [D] of the handlebar (rear view). Tighten the upper clamp bolt [E] first, and then the lower clamp bolt [F]. There will be a gap at the lower part of the clamp after tightening. Torque - Clutch Master Cylinder Clamp Bolts: 11 N·m (1. 1 kgf·m, 95 in·lb) · Use a new flat washer on each side of the clutch hose fitting. · Tighten the clutch hose banjo bolt. · Replenish the clutch fluid into the reservoir and bleed the clutch line (see Clutch Line Bleeding). · Check that the clutch line has proper fluid pressure and no fluid leakage. Clutch Master Cylinder Disassembly/Assembly placement in the Periodic Maintenance Chapter. Torque - Clutch Hose Banjo Bolt: 25 N·m (2. 5 kgf·m, 18 ft·lb) Refer to Clutch Master Cylinder Cup and Dust Seal Re 6-8 CLUTCH Clutch Master Cylinder Clutch Master Cylinder Inspection · Disassemble the clutch master cylinder. or pitting on the that no scratches, · Checkof thethere arecylinder [A] and rustthe outside of the inside master on · piston [B]. If a cup is worn, damaged, softened (rotted), or swollen, the piston assembly should be replaced to renew the cups. If fluid leakage is noted at the clutch lever, the piston as sembly should be replaced to renew the cups. If it is damaged, replace it. · · · that · Checksmallthe relief and supply ports are not plugged. [. . . ] Press by hands: Clamp the harness [5] with these clamps [4] and press each end of clamps by hands against the rear fender. 17-14 APPENDIX Cable, Wire, and Hose Routing F: Front Connect the following connectors in the order numbered and locate them as shown. Insert the oil pressure/neutral switch leads, sidestand switch leads, and regulator/rectifier leads in this order between the alternator cover and the clutch slave cylinder. APPENDIX 17-15 Cable, Wire, and Hose Routing F: Front T: Top 1. Raise the lock to discon nect. 17-16 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-17 Cable, Wire, and Hose Routing F: Front : Vacuum Pulsation : Bypass Air Flow #1: For Front Cylinder #2: For Rear Cylinder 1. Rubble Plug (except California) 17-18 APPENDIX Cable, Wire, and Hose Routing F: Front 1. [. . . ]