User manual KAWASAKI VULCAN 1600 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. [. . . ] 90 °C (194 °F) 340 440 kPa (3. 5 4. 5 kgf/cm², 50 64 psi) ENGINE LUBRICATION SYSTEM 7-7 Special Tools and Sealant Oil Pressure Gauge, 5 kg/cm² : 57001­125 Filler Cap Driver : 57001­1454 Oil Pressure Gauge Adapter, PT 1/8 : 57001­1033 Kawasaki Bond (Silicone Sealant) : 56019­120 Oil Filter Wrench : 57001­1249 7-8 ENGINE LUBRICATION SYSTEM Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine or transmission seizure, accident, and injury. Oil Level Inspection the vertical. · Situate that motorcycle so that itisisbetween the upper [A] the engine oil · Check [B] levels in thelevel and lower gauge. Clutch Cover [C] Situate the motorcycle so that it is perpendicular to the ground. If the motorcycle has just been used, wait 2 3 minutes for all the oil to drain down. If the oil has just been changed, start the engine and run it for several minutes at idle speed. Stop the engine, then wait 2 3 minutes until the oil settles. NOTE CAUTION Racing the engine before the oil reaches every part can cause engine seizure. If the engine oil gets extremely low or if the oil pump or oil passages clog up or otherwise do not function properly, the oil pressure warning light will light. If this light stays on when the engine is running above idle speed, stop the engine immediately and find the cause. If the oil level is too high, remove the excess oil, using a syringe or some other suitable device. If the oil level is too low, add the correct amount of oil through the oil filler opening. Use the same type and make of oil that is already in the engine. If the engine oil type and make are unknown, use any brand of the specified oil to top off the level in preference to running the engine with the oil level low. Then at your earliest convenience, change the oil completely. Engine Oil Change nance Chapter. NOTE Refer to the Engine Oil Change in the Periodic MainteOil Filter Replacement tenance Chapter. Refer to the Oil Filter Replacement in the Periodic Main- ENGINE LUBRICATION SYSTEM 7-9 Oil Pump and Oil Line Oil Pump Removal · Remove the engine (see Engine Removal/Installation chapter). · Split the crankcase (see Crankshaft/Transmission chapter). · Remove the oil pump mounting bolts [A], and take off the pump [B] out of the right crankcase. · Unscrew the relief valve [C] if necessary. · Remove:[A] Circlip Washer [B] Pump Shaft [C] Pump Gear [D] Oil Pump Installation oil shaft tang · Note the position of the thatpumptang fits into[A] and turn the pump gear shaft so the the slot [B] · · · of the oil pump gear. Replace the O-rings [C] with new ones if they are damaged. Tighten: Torque - Oil Pump Mounting Bolts: 11 N·m (1. 1 kgf·m, 97 in·lb) the · Check that right oil pump gear turns smoothly in the left side of the crankcase. Apply a non-permanent locking agent to the threads of · the relief valve and install it. Torque - Relief Valve: 15 N·m (1. 5 kgf·m, 11 ft·lb) Oil Hose Removal · Remove the engine (see Engine Removal/Installation chapter). · Remove:Case Cover (see Engine Top End chapter) Rocker · Oil Hose Flange Bolts [A] on Front and Rear Rocker Cases Oil Hose Banjo Bolt [B] on Right Crankcase behind Rear Cylinder Remove the front oil hose [C] and the rear oil hose [D]. Front [E] 7-10 ENGINE LUBRICATION SYSTEM Oil Pump and Oil Line Oil Hose Installation the · Run the front oil hose over first. rear oil hose as shown. Insert the rear oil hose [A] Next insert the front oil hose [B]. [. . . ] Fuel Tank Breather Hose (right, blue) 6. Vacuum Hose 17-48 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System (California Model) APPENDIX 17-49 Cable, Wire, and Hose Routing F: Front 1. Separator Vacuum Hose (white): Run it over the throttle cables and choke cable. Rear Cylinder Coolant Hose: Run it leftward the hose [6]. [. . . ]