User manual KAWASAKI VN1600 MEAN STREAK SERVICE MANUAL

[. . . ] VULCAN 1600 MEAN STREAK VN1600 MEAN STREAK 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 procedure. Bend the pages back to match the black tab of the desired chapter number 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 specific 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 MEAN STREAK VN1600 MEAN STREAK 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. [. . . ] · Remove: Clamp Bolts [A] Oil Pipe · Oil Pipe Holder Bolt [B] Remove the inside oil pipe [C] from the right crankcaes. ENGINE LUBRICATION SYSTEM 7-11 Oil Pump and Oil Line · Remove the oil pipe clamp bolt [A], and oil return pipe [B]. · Remove the separator [A]. · Remove: Clamp Bolt [A] Oil Pipe Oil Pipe Holder Bolt [B] Remove the inside oil pipe [C] and the oil return pipe [D] from the left crankcase [E]. Pull out the large size fittings [F] first, and remove the small size fitting [G] upward. · · Remove the bolt [A] and the separator [B]. Inside Oil Pipe Installation fitting O-rings · Replace the oil pipe O-rings before[A] with a new one. · Oil Pipe [B] Fitting [C] 7-12 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line inside oil pipe [A], · Install the[C] to left crankcaseseparator [B] and the oil return pipe [D] as shown. Do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet [E]. Apply silicone sealant to the crankcase mating surface [F] of the separator. Apply a non-permanent locking agent to the oil pipe holder bolt [H], oil return pipe clamp bolts [I], oil pipe clamp bolt [J] and oil baffle bolt [K]. If the oil nozzles [G] are removed, install them. Torque - Oil Pipe Holder Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Pipe Clamp Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Baffle Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Nozzles: 2. 9 N·m (0. 30 kgf·m, 26 in·lb) ENGINE LUBRICATION SYSTEM 7-13 Oil Pump and Oil Line the oil · Install pipeinside the pipe [A], separator [B], and the oil return [C] to right crankcase [D]. Do not apply silicone sealant to the groove of the grommet and the mating surface of the grommet [E]. Install the separator so that it's smaller side [F] faces inside. Apply a non-permanent locking agent to the oil pipe holder bolt [G], oil return pipe clamp bolts [H] and oil pipe clamp bolt [I]. If the oil nozzle [J] is removed, install it. · Install the removed parts. Torque - Oil Pipe Holder Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Return Pipe Clamp Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Pipe Clamp Bolt: 11 N·m (1. 1 kgf·m, 97 in·lb) Oil Nozzle: 2. 9 N·m (0. 30 kgf·m, 26 in·lb) Blowby Gas System Inspection that all the without · Be certainkinked, andhoses are routedcorrectly being flattened or are connected to the oil reserve tank and right air cleaner base. Inspect the breather hoses [A], breather pipe [B], and the air cleaner drain hose for damage or signs of deterioration. These hoses should not be hard and brittle, nor should be soft or swollen. Check that the hoses are securely connected. · · 7-14 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line Breather Drain Cleaning The air cleaner drain hose is provided beneath the right · · · air cleaner housing, and catches the water or oil from the crankcase breather hose. In the event that rain water is drawn in through the air cleaner or if engine oil is blown back, drain the housing. Remove the drain plug [A] from the air cleaner drain hose [B] to drain the water or breather. Install the plug on its original position. WARNING Be sure to reinstall the plug in the drain hose after draining. Oil on tires will make them slippery and can cause an accident and injury. ENGINE LUBRICATION SYSTEM 7-15 Oil Pressure Oil Pressure Measurement rubber boot [A]. · Slide out thethe oil pressure switch lead [B] from the terDisconnect · minal screw [C]. · Unscrew the oil pressure switch [D]. the oil · Attach hole. pressure gauge [B] and adapter [C] to the switch Oil Pressure Switch [A] Measure the oil pressure after the engine is warmed up. NOTE Special Tools - Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Oil Pressure Gauge Adapter, PT 1/8: 57001 -1033 the engine and warm up the engine. · Start the engine at the specified speed, and read the oil Run · pressure gauge. If the oil pressure is much lower than the standard, check the oil pump, oil pressure relief valve, and/or crankshaft bearing wear and con-rod big end bearing insert wear immediately. If the reading is much higher than the standard, check the oil screen first, and the oil passages for dirt or clogging. [. . . ] Accessory Lead Connectors (female) 17-38 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-39 Cable, Wire, and Hose Routing F: Front 1. Coolant Reserve Tank Hose (from the radiator cap to the coolant reserve tank) 7. Fuel Tank Breather Hose (except CA, Run the hose through the right hole of the bracket. ) 12. Fuel Tank Breather Hose (through the right hole of the bracket. ) 17-40 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-41 Cable, Wire, and Hose Routing F: Front T: Top 1. [. . . ]