Kawasaki VN1600 Nomad, KAWASAKI VULCAN VN 1500 & 1600

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VULCAN 1600 NOMAD
VN1600 CLASSIC TOURER
Motorcycle
Assembly & Preparation
Manual
Foreword
In order to ship Kawasaki vehicles as effi-
ciently as possible, they are partially disassem-
bled before crating. Since some of the most
commonly removed parts have a direct bear-
ing on a vehicle’s reliability and safety, consci-
entious pre-sale assembly and preparation be-
comes extremely important. Good setup pro-
cedures can prevent needless warranty claims
and give customers a greater sense of confi-
dence in Kawasaki and their Kawasaki Dealers.
This Assembly and Preparation Manual ex-
plains step by step procedures of the following
items for all Kawasaki motorcycles.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or less of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
correctly followed, could result in dam-
age to, or destruction of equipment.
1. Uncrating
2. Assembly
3. Preparation
NOTE
ż
This note symbol indicates points of particular
interest for more efficient and convenient op-
eration.
The selling dealer assumes sole responsibil-
ity for any unauthorized modifications prior to
sale. Refer to your Service Binder for any Ser-
vice Bulletins specifying Factory Directed Mod-
ifications (Special Claims) which must be per-
formed before the vehicle is ready for sale.
Whenever you see the following symbols
heed their instructions! Always follow safe
operating and maintenance practices.
Kawasaki Heavy Industries, Ltd. accepts no
liability for any inaccuracies or omissions in this
publication, although every possible measure
has been taken to make it as complete and ac-
curate as possible. All procedures and specifi-
cations subject to change without notice.
© 2004 Kawasaki Heavy Industries, Ltd.
Nov. 2004 (K)
 Table of Contents
Uncrating
...................................................................................... 3
Opening Crate ............................................................................. 3
Parts Check................................................................................. 4
Assembly
...................................................................................... 8
Handlebar .................................................................................... 8
Throttle Grip and Right Switch Housing ...................................... 8
Front Brake Master Cylinder ....................................................... 9
Left Switch Housing..................................................................... 9
Clutch Master Cylinder ................................................................ 10
Wiring Clamps ............................................................................. 10
Front Fender................................................................................
11
Front Wheel Installation...............................................................
12
Front Brake Hose Grommets ......................................................
14
Front and Rear Shift Pedals ........................................................
14
Front Footboard (Left) .................................................................
15
Front Guards (Left and Right) .....................................................
15
Helmet Locks...............................................................................
16
Rear Guards (Left and Right) ......................................................
16
Backrest Pad ...............................................................................
17
Horn.............................................................................................
17
Choke Knob.................................................................................
18
Rear View Mirrors (Left and Right) ..............................................
18
Windshield...................................................................................
19
License Plate Bracket..................................................................
21
Rear Reflectors and License Plate Holder ..................................
21
Left Saddlebag ............................................................................
22
Brake Disc Cleaning....................................................................
24
Preparation
...................................................................................
24
Battery Service ............................................................................
24
Front Brake Fluid.........................................................................
30
Rear Brake Fluid .........................................................................
31
Clutch Fluid .................................................................................
32
Rear Shock Absorber ..................................................................
34
Tire Air Pressures........................................................................
34
Fuel .............................................................................................
34
Coolant ........................................................................................
34
Engine Oil (4-stroke) ...................................................................
35
Final Gear Case Oil .....................................................................
36
Throttle Grip and Cable ...............................................................
37
Headlight Aim ..............................................................................
38
Idle Speed Adjustment ................................................................
38
Rear Brake Light Switch..............................................................
38
Fastener Check ...........................................................................
40
Standard Torque Table ................................................................
42
Test Ride the Motorcycle .............................................................
42
A & P Check List .........................................................................
42
UNCRATING 3
Uncrating
Opening Crate
•
Clear a space about 6 m (20 ft.) square to
give yourself plenty of space to work.
•
Place the crate upright on its base.
•
Remove the cardboard cover.
•
Remove the handlebar, front wheel, and the
parts box.
CAUTION
When you remove the crate bracket
from the motorcycle, be careful not to
drop any parts and bracket onto the
fuel tank and other components, and
not to scratch the fuel tank by the crate
bracket. This could damage the fuel
tank or components.
•
Unscrew the four bolts to remove the front
brake and clutch master cylinders.
•
Remove the two bracket bolts and the crate
bracket and discard them.
A. Lower Bolts
B. Upper Bolts
C. Crate Bracket
•
Take out all the bolts and screws and remove
the top and sides of the crate.
A.Bolts
B. Bolt
C. Front Master Cylinder
D. Crate Bracket
E. Clutch Master Cylinder
•
Unscrew the two lower bolts, and then re-
move the two upper bolts and crate bracket.
Discard the bolts and bracket.
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