VULCAN 1600 NOMAD

VN1600 CLASSIC TOURER

MotorcycleAssembly & Preparation

Manual

ForewordIn order to ship Kawasaki vehicles as effi-

ciently as possible, they are partially disassem-bled before crating. Since some of the mostcommonly 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 claimsand 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 followingitems for all Kawasaki motorcycles.

1. Uncrating2. Assembly3. Preparation

The selling dealer assumes sole responsibil-ity for any unauthorized modifications prior tosale. 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 safeoperating and maintenance practices.

WARNINGThis warning symbol identifies specialinstructions or procedures which, if notcorrectly followed, could result in per-sonal injury, or less of life.

CAUTIONThis caution symbol identifies specialinstructions or procedures which, if notcorrectly followed, could result in dam-age to, or destruction of equipment.

NOTEThis note symbol indicates points of particularinterest for more efficient and convenient op-eration.

Kawasaki Heavy Industries, Ltd. accepts noliability for any inaccuracies or omissions in thispublication, although every possible measurehas 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 ...................................................................................... 3Opening Crate ............................................................................. 3Parts Check................................................................................. 4

Assembly ...................................................................................... 8Handlebar.................................................................................... 8Throttle Grip and Right Switch Housing ...................................... 8Front Brake Master Cylinder ....................................................... 9Left Switch Housing..................................................................... 9Clutch Master Cylinder ................................................................ 10Wiring Clamps ............................................................................. 10Front Fender................................................................................ 11Front Wheel Installation............................................................... 12Front Brake Hose Grommets ...................................................... 14Front and Rear Shift Pedals ........................................................ 14Front Footboard (Left) ................................................................. 15Front Guards (Left and Right) ..................................................... 15Helmet Locks............................................................................... 16Rear Guards (Left and Right) ...................................................... 16Backrest Pad ............................................................................... 17Horn............................................................................................. 17Choke Knob................................................................................. 18Rear View Mirrors (Left and Right) .............................................. 18Windshield................................................................................... 19License Plate Bracket.................................................................. 21Rear Reflectors and License Plate Holder .................................. 21Left Saddlebag ............................................................................ 22Brake Disc Cleaning.................................................................... 24

Preparation ................................................................................... 24Battery Service ............................................................................ 24Front Brake Fluid......................................................................... 30Rear Brake Fluid ......................................................................... 31Clutch Fluid ................................................................................. 32Rear Shock Absorber .................................................................. 34Tire Air Pressures........................................................................ 34Fuel ............................................................................................. 34Coolant ........................................................................................ 34Engine Oil (4-stroke) ................................................................... 35Final Gear Case Oil ..................................................................... 36Throttle Grip and Cable ............................................................... 37Headlight Aim .............................................................................. 38Idle Speed Adjustment ................................................................ 38Rear Brake Light Switch.............................................................. 38Fastener Check ........................................................................... 40Standard Torque Table ................................................................ 42Test Ride the Motorcycle ............................................................. 42A & P Check List ......................................................................... 42

UNCRATING 3

UncratingOpening Crate•Clear a space about 6 m (20 ft.) square togive yourself plenty of space to work.• Place the crate upright on its base.•Remove the cardboard cover.•Remove the handlebar, front wheel, and theparts box.

CAUTIONWhen you remove the crate bracketfrom the motorcycle, be careful not todrop any parts and bracket onto thefuel tank and other components, andnot to scratch the fuel tank by the cratebracket. This could damage the fueltank or components.

•Unscrew the four bolts to remove the frontbrake and clutch master cylinders.•Remove the two bracket bolts and the cratebracket and discard them.

A. BoltsB. BoltC. Front Master CylinderD. Crate BracketE. Clutch Master Cylinder

•Unscrew the two lower bolts, and then re-move the two upper bolts and crate bracket.Discard the bolts and bracket.

A. Lower BoltsB. Upper BoltsC. Crate Bracket

•Take out all the bolts and screws and removethe top and sides of the crate.

4 UNCRATING

Parts Check•Open the parts box, and check the parts against the illustrations. There may be minor differencesbetween these illustrations and the actual vehicle parts. In the following charts under Remarks, D= diameter in millimeters, L = length in millimeters, and T = Thickness in millimeters.

UNCRATING 5

No. Part Name Qty Remarks1 Handlebar with Grip 1

Handlebar Clamp 2Clamp Bolt, Socket 4 D = 10, L = 23Plastic Plug, Clamp Bolt 4 LargeThrottle Grip 1Clamp, Master Cylinder 2Clamp Bolt, Master Cylinder, Socket 4 D = 6, L = 20Plastic Plug, Clamp Bolt 4 SmallPlastic Clamp, Wiring and Hose 4 L = 88.5Screw, Switch Housing, LH & RH 4 D = 5, L = 25Rear View Mirror, LH & RH 2

2 Front Wheel 1Axle Collar, LH & RH 2 L = 46.5Front Fender with Brace 1Socket Bolt, Front Fender 4 D = 8, L = 35

3 For US and CN ModelsBrake Hose Clamp, LH & RH 2Grommet, Brake Hose 2Front Reflector, LH & RH 2Flanged Nut, Reflector 2 D = 5

4 For other than US and CN ModelsBrake Hose Clamp, LH & RH 2Grommet, Brake Hose 2

5 Front Left Footboard Assembly 1Flanged Bolt, Front Footboard, LH 2 D = 10, L = 30Front Guard, LH & RH 2Flanged Bolt, Front Guard 2 D = 10, L = 25Warning Label, Front Left Guard 1 US and CN Models OnlyFront Shift Pedal 1Rear Shift Pedal 1Flanged Bolt, Front and Rear Shift Pedals 2 D = 8, L = 25

6 Rear Guard, LH & RH 2Flanged Bolt with Washer, Rear Guard, Upper 2 D = 8, L = 30Socket Bolt, Rear Guard, Lower 2 D = 10, L = 50Plastic Plug, Socket Bolt, Rear Guard 2 LargeFlanged Bolt, Rear Guard 4 D = 8, L = 35Cap Nut, Rear Guard 4 D = 8Helmet Lock 2 Located in the left side cover.Screw with Non-permanent locking agent, Helmet Lock 2 D = 5, L = 12Warning Label, Rear Left Guard 1 US and CN Models Only

7 Backrest Pad 1Backrest Frame 1Cover with Mark, Backrest 1Cap Nut, Cover 4 D = 6Bolt, Backrest Frame 4 D = 8, L = 50Nut, Backrest Frame 4 D = 8

6 UNCRATING

* :European Models Only

UNCRATING 7

No. Part Name Qty Remarks8 Horn with Bracket 1Flanged Bolt, Horn 1

9 License Plate Bracket 1Bolt, Bracket, License Plate 2 D = 6, L = 12Bracket, Reflector 1 (US)(CN)(AUS) onlyReflector 3 (US)(CN) onlyReflector 1 (AUS) onlyCap Nut, Reflector 3 D = 5, (US)(CN) onlyCap Nut, Reflector 1 D = 5, (AUS) onlyCap Nut, Black, License Plate 4 D = 6, (US) onlyCap Nut, Black, License Plate 2 D = 6, (CN)(AUS)(EUR) onlyFlat Washer, Black, Holder, License Plate 4 D = 6.5 × 20 × 1.6, (US) onlyFlat Washer, Black, Holder, License Plate 2 D = 6.5 × 20 × 1.6, (CN) (AUS)(EUR) onlyHolder, License Plate 1Bolt with Flat Washer 7 D = 6, L = 14 (US only)Bolt with Flat Washer 5 D = 6, L = 14, (CN)(AUS)(EUR) onlyCap Nut, Holder, License Plate 3 D = 6

10 Windshield Assembly with 1Center Plate, Outer & Inner (2)Damper, Center Plate, Outer & Inner (2)Socket Bolt with Washer, Center Plate (4) D = 6, L = 20Cap Nut (10) D = 6Vulcan Mark (1) (US)(CN)(AUS) onlyVN1600 Mark (1) (EUR) onlyOuter Plate, LH & RH (2)Inner Plate, LH & RH (2)Outer Damper, Outer Plate, LH & RH (2)Inner Damper, Inner Plate, LH & RH (2)Socket Bolt with Washer, Outer & Inner Plate (6) D = 6, L = 25Sub-windshield (1)Stay, Windshield, LH & RH (2)

Trim, Windshield 1 L = 1 900, (EUR) onlyClamp, Trim 2 (EUR) onlySocket Bolt, Stay 4 D = 8, L = 10Bracket, Windshield, LH & RH 2Socket Bolt, Bracket, Upper 2 D = 8, L = 20Socket Bolt, Bracket, Lower 2 D = 8, L = 25

11 Outer Plate, Deflector, LH & RH 2Deflector, LH & RH 2Stay, LH & RH 2Socket Bolt with Washer 4 D = 6, L = 16Cap Nut 4 D = 6Socket Bolt, Stay 4 D = 6, L = 16

12 Saddlebag, LH 1Lock, Saddlebag 1 Located in the left side cover.Damper, Bottom 2 LargeDamper, Upper 2 D = 12Flanged Collar 2 D = 12, L = 13.1Flanged Bolt, Saddlebag 2 D = 8, L = 75Flat Washer, Saddlebag, Black 4 D = 8.5 × 20, T = 1.6

13 Battery Electrolyte, FTZ16-BS 114 Owner’s Manual 1

AUS: Australian Model EUR: European ModelCN: CN Model US: United States Model

8 ASSEMBLY

AssemblyHandlebar

NOTEPosition the handlebar clamp on the handle-bar with the slanted side facing rearward.

•Set the handlebar to match its punched markto the rear portion of the lower clamp matingface and install the upper clamps and bolts (D= 10, L = 23).

A. Front BoltsB. Slanted SideC. GapD. Punched MarkE. No GapF. Forward

Handlebar Clamp Bolt Tightening•Tighten the front clamp bolts first, and thenthe rear clamp bolts to the specified torque.There will be a gap at the rear part of theclamp after tightening.Torque: 34 N·m (3.5 kgf·m, 25 ft·lb)

•Push the large plastic plugs (4) into the han-dlebar clamp bolts.

A. Plastic PlugsB. Handlebar Clamps

Throttle Grip and Right SwitchHousingAlignment Pin Type•Apply a light coat of grease on the exposedportion of the throttle inner cables.• Fit both throttle cable tips into the nearestsocket in the throttle grip.

A. Front Half (Right Switch Housing)B. Throttle Cable (Accelerator)C. Cable Tips: Apply Grease.D. Throttle GripE. Throttle Cable (Decelerator)F. Rear Half (Right Switch Housing)

•Fit the two halves of the right switch housingso that the pin on the front half fits into thehole in the handlebar.

A. HoleB. PinC. Front Half

• Insert the two screws (D = 5, L = 25) andtighten them.• Tighten the holder screw.•Check that the throttle grip moves smoothlyfrom full open to close, and the throttle closesquickly and completely.

ASSEMBLY 9

A. Right Switch HousingB. Screws (L = 25)C. HarnessD. Throttle Cable (Accelerator)E. Throttle Cable (Decelerator)F. Holder Screw

Front Brake Master Cylinder•Connect the right switch housing lead con-nectors to the front brake light switch termi-nals on the front brake master cylinder.• Apply silicone grease or PBC grease to themaster cylinder clamp bolts.• Install the front master cylinder with its clampand the two socket bolts (D = 6, L = 20).

A. Front Master CylinderB. Punched MarkC. ClampD. Socket BoltsE. HarnessF. Front Brake Light SwitchG. Connectors and Dust Covers

•Position the master cylinder so that the gapbetween the front and rear master cylinderclamps aligns with the punched mark on thehandlebar.• Tighten the upper clamp bolt first and then thelower bolt to the specified torque.Torque: 8.8 N·m (0.90 kgf·m, 78 in·lb)

•Push the small plastic plugs (2) into the mas-ter cylinder clamp bolts.

A. Plastic PlugsB. Master Cylinder

Left Switch Housing•Fit the two halves of the left switch housingtogether so that the vertical parting line of thefront and rear halves align with the punchedmark on the handlebar.

A. Punched MarkB. Rear Half (Left Switch Housing)C. Front HalfD. Screws (L = 25)E. Harness

• Insert the two screws (D = 5, L = 25) andtighten them securely.

10 ASSEMBLY

Clutch Master Cylinder•Apply silicone grease or PBC grease to themaster cylinder clamp bolts.• Install the clutch master cylinder with itsclamp and the two socket bolts (D = 6, L =20).• Position the master cylinder so that the gapbetween the front and rear master cylinderclamps aligns with the punched mark on thehandlebar.

A. ClampB. Clutch Master CylinderC. Punched MarkD. Connector and Dust CoverE. Starter Lock-out SwitchF. HarnessG. Socket Bolts

•Connect the connector of the left switch hous-ing to the starter lock-out switch on the mastercylinder.• Tighten the upper clamp bolt first and then thelower bolt to the specified torque.Torque: 11 N·m (1.1 kgf·m, 97 in·lb)

•Push the small plastic plugs (2) into the clutchmaster cylinder clamp bolts.

A. Plastic PlugsB. Clutch Master Cylinder

Wiring Clamps•Fasten the front brake hose and the rightswitch housing harness to the right side ofthe handlebar with two plastic clamps.

NOTEThe plastic clamp at the inside fastens theright switch harness only.

A. Handlebar (Right Side)B. Plastic ClampsC. Front Brake HoseD. Right Switch Harness

•Fasten the clutch hose and the left switchhousing harness to the left side of the han-dlebar with two plastic clamps.

A. Handlebar (Left Side)B. Plastic ClampsC. Clutch HoseD. Left Switch Harness

ASSEMBLY 11

A. Left Switch LeadB. Clutch HoseC. Fasten the left switch lead and the clutch hose with two plastic clamps.D. Fasten the right switch lead with the plastic clamp.E. Fasten the right switch lead and the brake hose with the plastic clamp.F. Throttle CablesG. Brake HoseH. Right Switch LeadI. Handlebar

Front FenderFront Reflectors (for US and CN Modelsonly)•Assemble the front left and right reflectors andthe brake hose clamps with the nut (D = 5) oneach.

A. Front Brake Hose Clamp (Left)B. Front Brake Hose Clamp (Right)C. Front ReflectorsD. Nuts

12 ASSEMBLY

Front Fender Installation• Lift the motorcycle off the crate base and sup-port the motorcycle with a suitable stand orjack.• Loosen the axle clamp bolts on the right forkleg and remove the front axle.• Loosen the two flanged bolts (D = 10, L = 47)to remove each front brake caliper.

A. Front Brake CalipersB. Flanged Bolts (D = 10, L = 47)

CAUTIONDo not leave the calipers hanging bythe brake hoses. After removing thecalipers, secure them to the frame usinga suitable band.

• Install the front fender with its more roundedend facing forward.

A. Front FenderB. Forward

• Install the front fender on the fork legs, and in-stall the front left and right brake hose clampson the inside of the fender with the four bolts(D = 8, L = 35) and tighten them.

US and CN Models

A. Front FenderB. Bolts (D = 8, L = 35)C. Brake Hose Clamp (Left)

Other than US and CN Models

A. Front FenderB. Bolts (D = 8, L = 35)C. Brake Hose Clamp (Left)

Front Wheel Installation•Check the wheel rotation mark on the fronttire.

NOTEThe direction of the wheel rotation is shownby an arrow on the front tire. Install the wheelso that the rotation mark coincides with wheelrotational direction.

ASSEMBLY 13

A. Front TireB. ArrowC. Rotation

•Fit the axle collars on both sides of the frontwheel hub. The collars are identical.• Put the front wheel assembly between thefork legs.• Insert the front axle from the right side of thewheel and push it completely through.

A. Front AxleB. Collar (Right)C. Axle Clamp Bolts (Right)D. Collar (Left)

•Tighten the front axle to the specified torque.Torque : 108 N·m (11.0 kgf·m, 80 ft·lb)

•Temporary install the front brake calipers.• Before tightening the axle clamp bolts on theright fork leg, pump the front fork up and down4 or 5 times to align the right front fork leg andto seat the front axle. Do not pull the brakelever when pumping the fork.

NOTEDo not apply the front brake during thisprocess to stop the motorcycle from rollingforward. Put a block in front of the front wheelto prevent movement.

A. Pump the fork up and down.B. Block

•Tighten the axle clamp bolts on the right forkleg to the specified torque.Torque : 29 N·m (3.0 kgf·m, 21 ft·lb)

NOTETighten the two front axle clamp bolts alter-nately two times to ensure even tighteningtorque.

•Check the clearance between the right forkleg and the axle collar with a thickness gauge.There should be about 2.0 mm (0.08 in.) ofclearance. The clearance between 1.05 ~3.19 mm (0.04 ~ 0.13 in.) is acceptable.

A. Right Fork LegB. Front AxleC. Axle Clamp BoltsD. About 2.0 mm (0.08 in.)E. Collar (Right)

• If the clearance is out of this range, removethe front wheel and check the axle, wheel huband other related parts for damage.• Tighten both front brake caliper mountingbolts (D = 10, L = 47) to the specified torque.Torque : 34 N·m (3.5 kgf·m, 25 ft·lb)

14 ASSEMBLY

•Check the front brake.

A. Front Brake Caliper (Left)B. Bolts (D = 10, L = 47)

WARNINGDonot attempt to ride themotorcycle un-til a full brake lever is obtained by pump-ing the brake lever until the pads areagainst the disc. The brake will not func-tion on the first application of the lever ifthis is not done.

Front Brake Hose Grommets•Fit the grommet onto each front left and rightbrake hose, and install it in the clamp.

US and CN Models

A. Front Brake Hose (Left)B. GrommetC. Brake Hose Clamp (Left)

Other than US and CN Models

A. Front Brake Hose (Left)B. GrommetC. Brake Hose Clamp (Left)

Front and Rear Shift Pedals

NOTEInstall the front and rear shift pedals after the“Clutch Fluid” section in the Preparation chap-ter.

• Install the front shift pedal on the shift shaftaligning the punched marks on the pedal andthe shaft.• Install the pedal bolt (D = 8, L = 25) andtighten it to the specified torque.Torque : 30 N·m (3.1 kgf·m, 22 ft·lb)

• Install the rear shift pedal with the bolt (D =8, L = 25) in the same way as the front shiftpedal.

A. Front Shift PedalB. Bolt (D = 8, L = 25)C. Align the Punched Marks.D. Rear Shift PedalE. Shift Shaft

ASSEMBLY 15

Front Footboard (Left)

NOTEInstall the left footboard after the “Clutch Fluid”section in the Preparation chapter.

• Install the left footboard assembly on theframe with one bolt (D = 10, L = 30) at therear and tighten it.

A. Front Footboard (Left)B. Bolt (Rear)

NOTEThe bolt in front is for tightening the footboardand the front guard together.Tighten the front footboard mounting bolts af-ter installing the front guards to the specifiedtorque.

Front Guards (Left and Right)Front Guards Installation•Remove the front side mounting bolt from thefront right footboard.

A. Front Footboard (Right)B. Bolt

• Install both front left and right guards on theframe with the upper mounting bolts (D = 10,L = 25), and on the front footboard bracketswith the lower mounting bolts (D = 10, L = 30).

A. Front Guard (Left)B. Bolt (D = 10, L = 25)C. Bolt (D = 10, L = 30)D. Footboard Bracket

•Tighten the front footboard and the guardmounting bolts to the specified torque.Torque : 34 N·m (3.5 kgf·m, 25 ft·lb)

Label Installation (for US and CN Mod-els only)•Wipe off any oil or grease from the applicationarea.• Peel the warning label off the backing sheetand stick it on the center of the front left guard.

A. Front Guard (Left)B. Label For US Models (56070-1285)C. Label TopD. Label For CN Models (56070-1180)

16 ASSEMBLY

Helmet Locks•Unlock the helmet lock with the key and fitthe small projection of the lock into the holein the bracket of each rear guard and fastenit with the screw (D = 5, L = 12) having anon-permanent locking agent.• Lock the helmet lock.

A. Helmet LockB. Ignition KeyC. ProjectionD. ScrewE. Rear Guard (Left)

Rear Guards (Left and Right)Rear Guards Installation•Remove the right saddlebag.• Insert the ignition key into the lock and turnthe key counterclockwise and pull the knoboutward to open the lid.

A. Saddlebag (Right)B. Ignition KeyC. CounterclockwiseD. Knob

•Open the saddlebag lid and remove the bolts(D = 8, L = 75) inside the saddlebag, and thenpull it up.

A. Bolts (D = 8, L = 75)

• Join the rear left guard end and the left sad-dlebag/muffler bracket with the bolts (D = 8, L= 35)(2) and cap nuts (2) and tighten them.• Install the guard on the brackets with the up-per bolt (D = 10, L = 30) and the lower socketbolt (D = 10, L = 50) and tighten them.

A. Rear Guard (Left)B. Bolts (D = 8, L = 35) and Cap NutsC. Bolt (D = 10, L = 30)D. Socket Bolt (D = 10, L = 50)

•Push the large plastic plug into the top of thesocket bolt.

A. Plastic PlugB. Rear Guard (Left)

• Install the right guard in the same manner asthe left guard.

ASSEMBLY 17

Label Installation (for US and CN Mod-els only)•Wipe off any oil or grease from the applicationarea.• Peel the warning label off the backing sheetand stick it on the rear left guard.

A. Rear Guard (Left)B. Label For US Models (56070-1285)C. Label TopD. 20 mm (0.8 in.)E. Label For CN Models (56070-1180)

NOTEReinstall the right saddlebag after the “RearBrake Fluid” and “Rear Shock Absorber” sec-tions in the Preparation chapter. When in-stalling the right saddlebag, see “Left Saddle-bag” section in the Assembly chapter.

Backrest Pad•Assemble the backrest pad, frame, and coverwith the cap nuts (D = 6)(4).

A. Backrest PadB. CoverC. Cap Nut (D = 6)D. Frame

• Install the backrest between the brackets withthe flanged bolts (D = 8, L = 50)(4) and the capnuts (D = 8).• Tighten all the bolts and nuts securely.

A. BackrestB. Cap Nuts (D = 8)C. Bolts (D = 8, L = 50)

Horn•Connect the horn lead connectors (BK, BK)of the harness to the horn terminals at the leftside of the radiator.

A. HornB. Connectors (BK, BK)C. Bracket

• Install the horn with bracket to the frame withthe bolt (D = 8, L = 12) and tighten it.

18 ASSEMBLY

A. HornB. Bolt (D = 8, L = 12)C. Bracket

Choke Knob• Loosen the locknut and fasten the choke knobto the bracket with locknut.

A. Choke KnobB. LocknutC. Bracket

Rear View Mirrors (Left and Right)Conventional Type (Single Nut)• Loosen the locknut completely.• Screw the rear view mirror in completely, andthen back it two turns out.• Turn the mirror stay to assure visibility to therear with the operator sitting on the motorcy-cle and tighten the locknut securely.• Adjust the rear view mirror by slightly movingonly the mirror portion of the assembly.

A. LocknutB. Rear View Mirror (Left)

• Installation and adjustment of the right sidemirror is common with the left side. Followthe procedure specified for the left side.Turning Stay Type•Screw the mounting area of the left rear viewmirror into the holder all the way, and tightenthe lower hexagonal area securely.

A. Lower Hexagonal Area for TighteningB. Upper Hexagonal Area (Adapter)C. Rear View Mirror (Left)

CAUTIONDo not force to tighten and/or loosen theupper hexagonal area (adapter) with aspanner or wrench. Disassembly of thisarea is not possible. Non-permanentlocking agent is already applied to thethreads of this inner area. Forcible loos-ening may damage the adapter and/orthe turning mechanism of the stay.

ASSEMBLY 19

A. Lower Hexagonal Area for TighteningB. Upper Hexagonal Area (Adapter)C. StayD. Non-permanent Locking Agent applied.

•Turn the stay to assure visibility to the rearwith the operator sitting on the motorcycle.• Adjust the rear view mirror by slightly movingonly the mirror portion of the assembly.

A. StayB. Mirror

• Installation and adjustment of the right sidemirror is common with the left side. Followthe procedure specified for the left side.

WindshieldCAUTION

Be sure not to damage the surface of thewindshield when installing or handling.

A. Windshield Assembly

•Remove the dummy bolts on the fork coverand discard them.

A. Fork CoverB. Dummy Bolts (Right Side)

• Install the left and right mounting brackets onthe fork cover with the socket bolts (D = 8, L= 20)(D = 8, L = 25).

A. Mounting Bracket (Right)B. Socket Bolt (D = 8, L = 20)C. Socket Bolt (D = 8, L = 25)

• Install the windshield assembly on the mount-ing brackets with the socket bolts (D = 8, L =10)(4).• Set the windshield all the way down andtighten the bolts securely.

20 ASSEMBLY

A. Windshield AssemblyB. Socket Bolts (D = 8, L = 10)

Trim Installation [EUR Models Only]•Fit the windshield trim onto the edge of thewindshield starting from each lower edge.• Fix the trim ends with the clamps (2).

A. TrimB. Clamps

Deflectors (Left and Right) Installation•Assemble the left and right stays, deflectors,and outer plates with the socket bolts (D = 6,L = 16)(4) and cap nuts (D = 6)(4).

A. Stay (Left)B. DeflectorC. Outer PlateD. Socket Bolts (D = 6, L = 16)E. Stay (Right)F. Cap Nuts

• Install each deflector on the bracket with thesocket bolts (D = 8, L = 10)(2) for each sideand tighten them.

A. Deflector (Right)B. Socket Bolts (D = 8, L = 10)

Windshield Height AdjustmentThe windshield can be adjusted 50 mm (2 in.)

in height to suit the rider’s preference.• Loosen both the upper and lower bolts oneach lower side of the windshield and moveit up or down.• Align both the left and right windshield stays.• Tighten the bolts securely.

A. WindshieldB. BoltsC. Positioning Marks

Sub-windshield Adjustment• Loosen the windshield bolts on the left andright vertical outer plates and move the sub-windshield up or down. The distance shouldbe 10 mm (0.04 in.) between the lower edgeof the sub-windshield and the headlight body.• Tighten the windshield bolts.

ASSEMBLY 21

A. BoltsB. Sub-windshield

License Plate BracketLicense Plate Bracket Installation• Install the license plate bracket onto the rearfender with the bolts (D = 6, L = 12)(2).

A. Rear FenderB. License Plate BracketC. Bolts (D = 6, L = 12)

Rear Reflectors and License PlateHolder

US and CN Models only•Assemble the rear reflectors, bracket, and li-cense plate holder with the cap nut (D = 5) oneach.

A. ReflectorsB. Reflector BracketC. License Plate HolderD. Cap Nuts (D = 5)

• Install the license plate holder and the rearreflector bracket on the license plate bracketwith the bolts (D = 6, L = 14)(3) and platedcap nuts (3) and tighten them. The remainingfasteners are used for the license plate.

A. License Plate HolderB. Reflector BracketC. Bolt (D = 6, L = 14)D. Cap NutE. License Plate BracketF. For US ModelsG. For CN Models

AUS Models only• Install the rear reflector on the license plateholder with the cap nut (D = 5) and tighten it.

22 ASSEMBLY

A. ReflectorB. License Plate HolderC. Cap Nut (D = 5)

• Install the license plate holder on the licenseplate bracket with the bolts (D = 6, L = 14)(3)and plated cap nuts (3) and tighten them. Theremaining fasteners are used for the licenseplate.

A. License Plate HolderB. Bolt (D = 6, L = 14)C. Cap NutD. License Plate Bracket

Other than US, CN, and AUS Modelsonly• Install the license plate holder on the licenseplate bracket with the bolts (D = 6, L = 14)(3)and plated cap nuts (3) and tighten them. Theremaining fasteners are used for the licenseplate.

A. License Plate HolderB. Bolt (D = 6, L = 14)C. Cap NutD. License Plate Bracket

Left Saddlebag

NOTEInstall the saddlebags after the “Final GearCase Oil”, “Rear Brake Fluid”, and “RearShock Absorber” sections in the Preparationchapter.

Left Saddlebag Lid Lock Installation

NOTEAfter the saddlebag is installed, you can installthe left saddlebag lid lock.

• Inspect the saddlebags for damage.• Insert the ignition key into the lock, and turnthe key counterclockwise to the unlocked po-sition (hook faces left).•With the locked-position mark on the lock fac-ing up (toward the handle), insert the hookof the lock, then the lock into the hole in theleft saddlebag lid, and push it straight aheadso that the projections on the lock fit into thenotches

ASSEMBLY 23

A. LockB. Left SaddlebagC. Locked-position MarkD. ProjectionsE. Notches

NOTEPush the lid lock all the way into the hole inthe lid so that the projection ends are insertedinto it.

A. Lock

•Turn the key clockwise and counterclockwise,to check the saddlebag lid lock operation.Left Saddlebag Dampers Installation• Insert the large dampers (2) so that thegrooves fit into the holes in the lower brack-ets of the left saddlebag/muffler bracket.

A. Dampers

•Open the saddlebag lid, and insert the upperdampers (2) into the holes in the saddlebag.• Push the flanged collars (2) into the damper.

A. Upper DamperB. Collars

Left Saddlebag Installation

NOTEOnly use the flat washers (T = 1.6 mm) (4)to adjust the clearance [1.0 mm (0.04 in.) ormore] between the saddlebag upper dampersand the bracket, as needed.

•While aligning the protrusions on the bottomof the saddlebag with the holes in the lowerbracket, engage the hook on the back of thesaddlebag with the upper bracket, then pushit down.

A. SaddlebagB. ProtrusionC. HookD. Upper Bracket

24 PREPARATION

•Measure the clearances between both thefront and rear upper dampers and the up-per mounting bracket with the saddlebaglightly pushed by hand against the mountingbracket.• If the clearance is 1.0 mm (0.04 in.) or moreat the front and/or rear, adjust it. Insert one ortwo flat washer(s) between the upper damperand the mounting bracket until it is less than1.0 mm (0.04 in.) at the front and/or rear.

A. SaddlebagB. Top StayC. Upper BracketD. Upper DampersE. ClearanceF. Flat WasherG. Bolts

• If the clearance is less than 1.0 mm (0.04in.) at the front and/or rear, the flat washeris unnecessary.•Open the saddlebag lid and install the flangedbolts (D = 8, L = 75)(2), (through the flatwasher(s) if necessary) and tighten them se-curely.

A. Left SaddlebagB. Bolts (D = 8, L = 75)

•After the saddlebag is installed, open andclose the lid several times, and check forsmooth movement of the lid handle and lidlock operation. If they operate improperly,remove the bolts and readjust the clearance.• Install the right saddlebag in the same man-ner as the left saddlebag.

Brake Disc Cleaning•Clean the front and rear brake discs usingoilless solvent.

WARNINGIf not removed, the anticorrosive treat-ment applied to the brake disc surfacewill interfere with brake action, and anunsafe riding condition could result.

PreparationBattery ServiceThe battery used in this motorcycle is a sealed

type and never needs to be refilled. Follow theprocedure for activating a new battery to ensurethe best possible battery performance.Activating the battery requires two steps, fill-

ing the battery with electrolyte, and charging.Read the electrolyte safety label and the follow-ing procedures carefully before battery activa-tion.

CAUTIONIncorrect Battery Activation will reducebattery performance and service life. Besure to strictly follow the Battery Serviceinstructions in this Manual.

•Make sure to use the electrolyte packed in thecrate with the unit.•Make sure that the model name of the elec-trolyte container matches the model name ofthe battery. These names must be the same.

PREPARATION 25

Battery Model Name forVN1600–D1: FTZ16–BS

A. Model Name of the ElectrolyteB. Model Name of the Battery

CAUTIONSealed battery electrolyte has a higherconcentration of sulfuric acid. Eachcontainer contains the proper amountof electrolyte for its specific battery.Insufficient or incorrect electrolyte willreduce battery performance and servicelife. Electrolyte over capacity can leadto battery cracking or leaking and resultin corrosion damage to the vehicle.

Riders Seat Removal•Remove the bolt (D = 6, L = 14) and pull thepassenger’s seat rearward.

A. Bolt (D = 6, L = 14)B. Passenger’s Seat

•Remove the bolt (D = 6, L = 14) and pull therider’s seat rearward.

A. Rider’s SeatB. Bolt (D = 6, L = 14)

•Remove the screw (D = 6, L = 14) and pullthe right side cover outward to clear the pro-jections.

A. Right Side CoverB. Screw (D = 6, L = 14)C. Projections

•Unfasten the wiring clamp.•Remove the two battery holder nuts, and dis-connect the white 1 P (Pin), 2 P, and the 3 Pconnectors.•Disconnect the 6 P connector and removethe black diagnosis 4 P connector from theholder, and then unfasten the plastic clampon the bottom of the battery holder while lift-ing the holder.

26 PREPARATION

A. Wiring ClampB. 1 P Connector (Negative Lead)C. 2 P ConnectorD. 3 P ConnectorE. Battery Holder NutsF. Battery HolderG. BatteryH. 6 P Connector (Rear Harness)I. 4 P Connector (Diagnosis)J. Plastic ClampK. 15 A Fuse HolderL. Harness (Fuel Pump)M. Harness (Fuel Gauge)

•Remove the 15 A fuse holder from the batteryholder, then remove the battery holder.

A. Battery HolderB. 15 A Fuse HolderC. ProjectionD. Screwdriver

•Take the battery out of the battery case.•Clean the terminals.Battery SpecificationsMake FurukawaBattery Type FTZ16-BSBattery Capacity 12 V 18 AhElectrolyte Capacity 0.82 LBattery/Electrolyte Set P/No. 26012-1371

Battery ActivationFilling the Battery with Electrolyte

CAUTIONDo not remove the aluminum sealingsheet [A] from the filler ports [B] untiljust prior to use. Be sure to use the ded-icated electrolyte container for correctelectrolyte volume.

•Place the battery on a level surface.• Check to see that the sealing sheet [A] has nopeeling, tears, or holes in it.• Remove the sealing sheet [A].

NOTEThe battery is vacuum sealed. If the sealingsheet has leaked air into the battery, it mayrequire a longer initial charge.

•Remove the electrolyte container from thevinyl bag.• Detach the strip of caps [A] from the containerand set aside, these will be used later to sealthe battery.

NOTEDo not pierce or otherwise open the sealedcells [B] of the electrolyte container. Do notattempt to separate individual cells.

PREPARATION 27

•Place the electrolyte container upside downwith the six sealed cells into the filler portsof the battery. Hold the container level, pushdown to break the seals of all six cells. Youwill see air bubbles rising into each cell as theports fill.

NOTEDo not tilt the electrolyte container.

•Check the electrolyte flow.• If no air bubbles [A] are coming up from thefiller ports, or if the container cells have notemptied completely, tap the container [B] afew times.

• Keep the container in place for 20 minutes ormore. Don’t remove the container from thebattery until it’s empty, the battery requires allthe electrolyte from the container for properoperation.

CAUTIONRemoval of the container before it iscompletely empty can shorten the ser-vice life of the battery. Do not removethe electrolyte container until it is com-pletely empty and 20 minutes haveelapsed.

•Gently remove the container from the battery.• Let the battery sit for 60 minutes prior tocharging to allow the electrolyte to permeateinto the plates for optimum performance.

NOTECharging the battery immediately after fillingcan shorten service life. Let the battery sit forat least 60 minutes after filling.

Initial Charge•Place the strip of caps loosely over the fillerports.

A. Strip

•Newly activated sealed batteries require aninitial charge.Standard Charge 1.8 A × 5 10 hours

• If using a recommended battery charger, fol-low the charger’s instructions for newly acti-vated sealed battery.

Kawasaki-recommended chargers:Optimate IIIYuasa 1.5 Amp Automatic ChargerBattery Mate 150–9

• If the above chargers are not available, useequivalent one.

NOTECharging rates will vary depending on howlong the battery has been stored, tempera-ture, and the type of charger used. Let batterysit 60 minutes after initial charge, then checkvoltage using a voltmeter. If it is not at least12.6 volts, repeat charging cycle.

•After charging is completed, press downfirmly with both hands to seat the strip ofcaps [A] into the battery (don’t pound or ham-mer). When properly installed, the strip ofcaps will be level with the top of the battery.

28 PREPARATION

CAUTIONOnce the strip of caps [A] is installedonto the battery, never remove the caps,nor add water or electrolyte to the bat-tery.

NOTETo ensure maximum battery life and customersatisfaction, it is recommended the battery beload tested at three times its amp-hour ratingfor 15 seconds.Re-check voltage and if less than 12.6 voltsrepeat the charging cycle and load test. If stillbelow 12.6 volts the battery is defective.

Battery Installation•Turn the ignition switch OFF.• Place the battery into the battery case.

A. Negative Cable (–)B. Positive Cable (+)C. Battery HolderD. Plastic ClampE. BatteryF. 15 A Fuse HolderG. Run the positive cable (+) through

the guide in the right side of thebattery case.

•Pull the battery positive cable (+) downwardand through the guide in the right side of thebattery case, and then route the cable asshown.•Reinstall the 15 A fuse holder and the batteryholder, and then install the black diagnosis 4P connector on the holder and connect the 6P connector, and fasten the harness with theplastic clamp.

A. Pull the Positive Cable (+) downward.B. Positive Cable (+)C. BatteryD. 4 P Connector (Diagnosis)E. 6 P Connector (Rear Harness)F. 15 A Fuse HolderG. Wiring ClampH. 3 P ConnectorI. 2 P ConnectorJ. 1 P Connector (Negative Lead)K. Negative Cable (–)

•Connect the 1 P, 2 P, and 3 P connectors,and fasten the harness of the 2 P and 3 Pconnectors with the wiring clamp.• First connect the red capped positive cable(+) to the positive terminal, and then connectthe negative cable (–) to the negative termi-nal.• Put a light coat of grease on the terminals toprevent corrosion.• Cover the (+) terminal with its protective cap,and install the battery holder nuts and tightenthem.

NOTEInstall the right side cover after the “Coolant”section in the Preparation chapter.

PREPARATION 29

Viewed from Right

A. Positive Terminal (+)B. BatteryC. Positive Cable (+)D. ECU RelayE. Negative Cable (–)

Viewed from Top

A. Negative Cable (–)B. Run the Positive Cable (+) through

the Guide in the Battery Case.C. Positive Cable (+)D. BatteryE. 4 P Connector (Diagnosis)F. 6 P Connector (Rear Harness)G. Plastic ClampH. 15 A Fuse HolderI. ECU ConnectorJ. 3 Connectors (1 P, 2 P, 3 P)

Rider’s Seat Installation• Insert the projection at the front of the rider’sseat into the receptacle on the frame.

A. ProjectionB. Receptacle

• Install the bolt (D = 6, L = 14) and tighten it.

A. Rider’s SeatB. Bolt (D = 6, L = 14)

• Insert the projection at the front of the passen-ger’s seat into the receptacle on the frame.

A. ReceptacleB. Projection

• Install the bolt (D = 6, L = 14) and tighten it.

30 PREPARATION

A. Bolt (D = 6, L = 14)B. Passenger’s Seat

Front Brake FluidFront Brake Fluid Level Inspection•With the front brake fluid reservoir held hori-zontal, check that the fluid level is above thelower level line.

A. Front Brake Fluid ReservoirB. Lower Level Line

• If the fluid level in the reservoir is lower thanthe lower level line, check for fluid leaks in thefront brake lines and fill the reservoir.• Loosen the screws to remove the front brakefluid reservoir cap and diaphragm.• Fill the reservoir to the upper level line withDOT4 brake fluid. Inside the front brakereservoir is a stepped line showing the upperlevel line.

A. Front Brake Fluid ReservoirB. Upper Level Line

WARNINGNever reuse old brake fluid.Do not use fluid from a container thathas been left unsealed or that has beenopen for a long time.Do not mix two types of fluid for use inthe brakes. This lowers the brake fluidboiling point and could reduce brake ef-fectiveness. It may also cause the rub-ber brake parts to deteriorate.Don’t leave the reservoir cap off for anylength of time to prevent moisture con-tamination of the fluid.Don’t add or change brake fluid in therain or during conditions of blowing dustor debris.

CAUTIONBrake fluid quickly ruins painted sur-faces. Wipe up any spilled fluid immedi-ately.

•Operate the brake lever several times.• If it feels spongy, there might be air in thebrake line.• If necessary, bleed the air in the front brakelines.• Also check for fluid leakage around the fit-tings.Front Brake Line Air Bleeding•Remove the reservoir cap and diaphragm,and check that there is plenty of fluid in thereservoir.

NOTEThe fluid level must be checked several times,during the bleeding operation and replenishedas necessary. If the fluid in the reservoir runscompletely out any time during bleeding, thebleeding operation must be repeated from thebeginning since air will have entered the line.

PREPARATION 31

•Attach a clear plastic hose to the bleed valveon each front brake caliper and run the otherend of the hose into a container.•With the reservoir cap off, slowly pump thebrake lever several times until no air bubblescan be seen rising up through the fluid fromthe holes at the bottom of the reservoir. Thisbleeds the air from the brake master cylinderend of the line.• Pump the brake lever a few times until itbecomes hard and then, holding the leversqueezed, quickly open (turn counterclock-wise) and close the bleed valve. Then releasethe lever. Repeat this operation until no moreair can be seen coming out into the plastichose.

A. Hold the brake lever applied.B. Quickly open and close the bleed

valve.C. Release the brake lever.

•Repeat the previous step one more time forthe other front disc brake.•When air bleeding is finished, check that thefluid level is between the upper and lowerlevel lines.• Install the diaphragm and reservoir cap.• Tighten the bleed valve(s) to the specifiedtorque.Torque: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•Apply the brake forcefully for a few seconds,and check for fluid leakage around the fittings.

Rear Brake FluidRear Brake Fluid Level Inspection•With the rear brake fluid reservoir held hor-izontal, check that the fluid level is betweenthe upper and lower level lines.

A. Rear Brake Fluid ReservoirB. CoverC. Upper Level LineD. Lower Level Line

• If the fluid level in the reservoir is lower thanthe lower level line, check for fluid leaks in thebrake line, and fill the reservoir.• Loosen the bolt to remove the cover from thereservoir.• Remove the reservoir cap and diaphragm,and fill the reservoir to the upper level line withDOT4 brake fluid.

CAUTIONBrake fluid quickly ruins painted sur-faces. Wipe up any spilled fluid immedi-ately.

NOTEFirst, tighten the rear brake fluid reservoir capclockwise by hand until slight resistance is feltindicating that the cap seated on the reser-voir body, then tighten the cap an additional1/6 turn while holding the brake fluid reservoirbody.

A. ReservoirB. CapC. ClockwiseD. 1/6 turn

32 PREPARATION

•Operate the brake lever several times.• If it feels spongy, there might be air in thebrake line.• If necessary, bleed the air in the rear brakeline.• Also check for fluid leakage around the fit-tings.Rear Brake Line Air Bleeding•Remove the rear brake reservoir cap and di-aphragm, and check that there is plenty offluid in the reservoir.

NOTEThe fluid level must be checked several times,during the bleeding operation and replenishedas necessary. If the fluid in the reservoir runscompletely out any time during bleeding, thebleeding operation must be repeated from thebeginning since air will have entered the line.

•Attach a clear plastic hose to the bleed valveon the rear brake caliper and run the otherend of the hose into a container.•With the reservoir cap off, slowly pump thebrake pedal several times until no air bub-bles can be seen rising up through the fluidfrom the holes at the bottom of the reservoir.This bleeds the air from the rear brake mastercylinder end of the line.• Pump the brake pedal a few times until itbecomes hard and then, holding the pedalpushed down, quickly open (turn counter-clockwise) and close the bleed valve. Thenrelease the pedal. Repeat this operation untilno more air can be seen coming out into theplastic hose.

A. Hold the brake pedal applied.B. Quickly open and close the bleed

valve.C. Release the brake pedal.

•When air bleeding is finished, check that thefluid level is between the upper and lowerlevel lines.• Tighten the bleed valve(s) to the specifiedtorque.Torque: 7.8 N·m (0.80 kgf·m, 69 in·lb)

• Install the diaphragm and reservoir cap.NOTE

First, tighten the rear brake fluid reservoir capclockwise by hand until slight resistance is feltindicating that the cap seated on the reser-voir body, then tighten the cap an additional1/6 turn while holding the brake fluid reservoirbody.

•Apply the brake forcefully for a few seconds,and check for fluid leakage around the fittings.• Install the cover with the bolt.Clutch FluidClutch Fluid Level Inspection•With the clutch reservoir held horizontal,check that the fluid level is above the lowerlevel line.

A. Clutch Fluid ReservoirB. Lower Level Line

• If the fluid level in the reservoir is lower thanthe lower level line, check for fluid leaks in theclutch line and fill the reservoir.

NOTESince the clutch fluid is the same as the brakefluid, refer to the “Front or Rear Brake Fluid”section for further details.

• Loosen the screws to remove the clutch fluidreservoir cap and diaphragm.• Fill the reservoir to the upper level line withDOT4 clutch fluid. Inside the clutch reservoiris a stepped line showing the upper level line.

PREPARATION 33

A. Clutch Fluid ReservoirB. Upper Level Line

•Operate the clutch lever several times.• If it feels spongy, there might be air in the line.• If necessary, bleed the air in the lines.• Also check for fluid leakage around the fit-tings.Clutch Line Air Bleeding• Loosen the mounting bolts to remove the al-ternator outer cover.

A. Alternator Outer CoverB. Socket Bolts and Washers

•Remove the reservoir cap and diaphragm,and check that there is plenty of fluid in thereservoir.

NOTEThe fluid level must be checked several timesduring the bleeding operation and replenishedas necessary. If the fluid in the reservoir runscompletely out any time during bleeding, thebleeding operation must be repeated from thebeginning since air will have entered the line.

•Attach a clear plastic hose to the bleed valveon the clutch slave cylinder and run the otherend of the hose into a container.•With the reservoir cap off, slowly pump theclutch lever several times until no air bubblescan be seen rising up through the fluid fromthe holes at the bottom of the reservoir. Thisbleeds the air from the clutch master cylinderend of the line.• Pump the clutch lever a few times until itbecomes hard and then, holding the leversqueezed, quickly open (turn counterclock-wise) and close the bleed valve.Then release the lever. Repeat this operationuntil no more air can be seen coming out intothe plastic hose.

A. Hold the clutch lever applied.B. Quickly open and close the bleed

valve.C. Release the clutch lever.

•When air bleeding is finished, check that thefluid level is between the upper and lowerlevel lines.• Install the diaphragm and reservoir cap.• Tighten the bleed valve to the specifiedtorque.Torque: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•Apply the clutch forcefully for a few seconds,and check for fluid leakage around the fittings.• Apply a soap and water solution or rubberlubricant to the body of the alternator coverbolts for easy installation.•Reinstall the alternator outer cover with thebolts and washers and tighten the bolts to thespecified torque.Torque: 6.9 N·m (0.70 kgf·m, 61 in·lb)

•Reinstall the front and rear shift pedals. See“Shift Pedal” section in the Assembly chapter.• Reinstall the left footboard assembly. See“Front Footboard (Left)” section in the Assem-bly chapter.

34 PREPARATION

Rear Shock AbsorberAir Pressure AdjustmentSTD Air pressure: Atmospheric

Rebound Damping Force Adjustment•Check the position of the rebound dampingforce adjuster at the upper end of each rearshock absorber. It has four positions. Thenumbers on the adjuster show the setting po-sition.

STD Rebound Damping Force:No. 2 position

A. Air ValveB. Rebound Damping Force AdjusterC. Number

•Turn the rebound damping force adjuster tothe No. 2 position.

Tire Air Pressures•To prevent flat-spotting during shipment, thetires are over-inflated before crating. Adjustthe pressures to the specified values in thefront and rear, and make sure to tighten thecaps securely.

Tire Air Pressure [when cold]:Front: 225 kPa (2.25 kgf/cm², 32 psi)Rear: 280 kPa (2.80 kgf/cm², 40 psi)

A. Tire Air Pressure Gauge

Fuel

WARNINGFill the tank in a well-ventilated area, andtake ample care that there are no sparksor open flames anywhere near the workarea.

•Open the fuel tank cap, and check for debrisin the fuel tank.• Fill the fuel tank with one gallon or four litersof unleaded gasoline. Use a gasoline with aminimum Antiknock Index rating according tothe recommendation of your country. Refer tothe following table.

The antiknock index is an average of the Re-search Octane Number (RON) and the MotorOctane Number (MON), as shown in the table.

Octane Rating Method MinimumRating

AntiknockIndex

(RON + MON)2 90

Research Octane Number(RON) 95

•Close the fuel tank cap, and check for anyleaks.

CoolantCoolant Level Inspection•Situate the motorcycle so that it is perpendic-ular to the ground.• Check the coolant level through the coolantlevel gauge. The coolant level should be be-tween the F (Full) and L (Low) marks.

NOTECheck the level when the engine is cold (roomor atmospheric temperature).

PREPARATION 35

A. F (Full) MarkB. L (Low) MarkC. Right Side Cover

Coolant Filling• If the amount of coolant is insufficient, removethe right side cover, pull open the cap from thereserve tank and add coolant through the filleropening to the F (Full) mark.

A. CapB. F (Full) MarkC. L (Low) Mark

• Install the cap.• To install the right side cover, insert the pro-jections into the grommets.• Tighten the screw.

A. Right Side CoverB. ProjectionsC. Grommets

NOTEA permanent type of antifreeze is installed inthe cooling system when shipped. It is col-ored green and contains ethylene glycol. It ismixed at 50 % and has the freezing point of –35°C (– 31°F).

Engine Oil (4-stroke)Engine Oil Level Inspection

NOTEThis vehicle’s engine is filled with 10W-40 oilfrom the factory. DO NOT DRAIN and refillthe crankcase before use. Check oil level anddrain plug tightness.

Engine Oil Drain Plug Torque:20 N·m (2.0 kgf·m, 14 ft·lb)

A. Oil Drain Plug

•Park the vehicle on level ground.• Before starting the engine, check that the en-gine has oil.• Check that the engine has oil through the oillevel sight gauge in the lower right side of theengine.

CAUTIONIf the engine is run without oil, it will beseverely damaged.

•Start the engine and run it for several minutesat idle speed. Stop the engine, then wait sev-eral minutes until the oil settles.•With the motorcycle held level, check the en-gine oil level through the oil level sight gauge.The oil level should come up between theH (High) and L (Low) level lines next to thegauge.

36 PREPARATION

A. Oil Filler CapB. Oil Level Sight GaugeC. H (High) Level LineD. L (Low) Level Line

• If the oil level is too high, remove the excessoil through the oil filler opening, using a sy-ringe or some other suitable device.• If the oil level is too low, add oil to reach thecorrect level. Use the same type of oil that isalready in the engine.•When replacing the cap, be sure the O-ring isin place, and tighten the cap.

Recommended Engine OilType: API SE, SF or SG

API SH or SJ with JASO MAViscosity: SAE 10W-40Capacity: 2.9 L (3.1 US qt)

[when filter is not removed]3.1 L (3.3 US qt)[when filter is removed]

Although 10W-40 engine oil is the recom-mended oil for most conditions, the oil viscositymay need to be changed to accommodateatmospheric conditions in your riding area.

Final Gear Case OilFinal Gear Case Oil Level Inspection•Have a helper hold the motorcycle vertical onlevel ground.• Remove the filler cap.• Check the oil level. If it is low, add oil asnecessary. The oil level should come to thebottom thread of the filler opening with themotorcycle held vertical on level ground.

A. Bottom ThreadB. Filler Cap

• If the oil level is too low, add the specified oil.• If the oil level is too high, remove the excessoil, using a syringe or some other suitabledevice.

WARNINGBe careful that no oil gets on the tire, rim,and brake disc. Clean off any oil thatinadvertently gets on them with oillesssolvent.

CAUTIONBe careful not to allow any dirt or foreignmaterials to enter the gear case.

NOTEUse the same type of oil that is already in thefinal gear case.

PREPARATION 37

•When replacing the filler cap, be sure the O-ring is in place, and install the cap.

Final Gear Case OilType: API “GL-5”

Hypoid gear oilViscosity: SAE 90 [above 5°C (41°F)]

SAE 80 [below 5°C (41°F)]Capacity: 0.2 L (0.21 US qt)

Final Gear Case Oil Drain Plug Torque:8.8 N·m (0.90 kgf·m, 78 in·lb)

A. Oil Drain Plug

•Reinstall the saddlebags. See “Left Saddle-bag” section in the Assembly chapter.

Throttle Grip and CableThrottle Grip Free Play Inspection• Inspect the throttle grip free play. If the freeplay is incorrect, adjust the throttle cables.

Throttle Grip Free Play:2 ~ 3 mm (0.08 ~ 0.12 in.)

•Check that the throttle grip moves smoothlyfrom full open to close, and the throttle closesquickly and completely in all steering posi-tions by the return spring. If the throttle gripdoes not return properly, check the throttle ca-ble routing, grip free play, and for possible ca-ble damage. Then lubricate the throttle ca-bles.

A. Throttle GripB. 2 ~ 3 mm (0.08 ~ 0.12 in.)

•Run the engine at idle speed, and turn thehandlebar all the way to the right and left toensure that the idle speed does not change.If the idle speed increases, check the throttlegrip free play.

WARNINGOperation with an improperly adjusted,incorrectly routed, or damaged cablecould result in an unsafe riding condi-tion.

Throttle Grip Free Play Adjustment• Loosen both locknuts of the throttle cablesand turn both adjusters in completely to givethe throttle grip plenty of play.• Turn out the decelerator cable adjuster untilthere is no play when the throttle grip is com-pletely closed. Tighten the locknut.

A. Accelerator CableB. Decelerator CableC. LocknutsD. Adjusters

•Turn out the accelerator cable adjuster un-til the specified amount of play is obtained.Tighten the locknut.

38 PREPARATION

Headlight AimThe headlight beam is adjustable both hori-

zontally and vertically. Headlight aim must becorrectly adjusted for safe riding as well as on-coming drivers. In most areas it is illegal to ridewith an improperly adjusted headlight.Horizontal Adjustment•Turn the horizontal adjusting screw on theheadlight rim in or out until the beam pointsstraight ahead.

A. Horizontal Adjusting ScrewB. Vertical Adjusting Screw

Vertical Adjustment•Turn the vertical adjusting screw on the head-light rim in or out to adjust the headlight verti-cally.

NOTEOn high beam, the brightest point should beslightly below horizontal with the motorcycleon its wheels and the rider seated. Adjustthe headlight to the proper angle according tolocal regulation.

Idle Speed Adjustment•Start the engine and warm it up thoroughly.• Adjust the idle speed to 900 ~ 1 000 r/min(rpm) by turning the idle adjusting screw.Idle Speed: 900 ~ 1 000 r/min (rpm)

A. Idle Adjusting Screw

•Open and close the throttle grip a few timesto make sure that the idle speed does notchange.•With the engine idling, turn the handlebar toeach side. If handlebar movement changesthe idle speed, check the throttle cable routingand free play.

WARNINGOperation with improperly routed, ordamaged throttle cables could result inan unsafe riding condition.

•Check for any exhaust leaks and correct ifnecessary.

Rear Brake Light SwitchRear Brake Light Switch Adjustment•Turn on the ignition switch. The brake lightshould illuminate when the brake pedal is de-pressed about 10 mm (0.4 in.)

A. Brake PedalB. 10 mm (0.4 in.)

• If it does not, turn the adjusting nut at the rearbrake light switch as required.

PREPARATION 39

A. Rear Brake Light SwitchB. Adjusting NutC. Lights sooner.D. Lights later.

CAUTIONTo avoid damaging the electrical con-nections inside the switch, be sure thatthe switch body does not turn during ad-justment.

40 PREPARATION

Fastener Check•The torque values listed are for assembly andpreparation items only, see the appropriateService Manual for a more comprehensivelist. Check tightness of all fasteners that arein the table before retail delivery. Also checkto see that each cotter pin or circlip is in place.

PREPARATION 41

TorqueNo. Fastener

N·m kgf·m ft·lbRemarks

Steering1 Handlebar clamp bolts 34 3.5 252 Steering stem head nut 88 9.0 65Brake3 Front master cylinder clamp bolts 8.8 0.90 78 in·lb S4 Front caliper mounting bolts (Left and Right) 34 3.5 255 Front brake bleed valves (Left and Right) 7.8 0.80 69 in·lb6 Rear master cylinder mounting bolts 25 2.5 187 Rear caliper mounting bolts 34 3.5 258 Rear brake bleed valves 7.8 0.80 69 in·lbWheel9 Front axle shaft 108 11.0 8010 Front axle clamp bolts (Right) 29 3.0 21 ALSuspension

11 Rear shock absorber mounting nuts (Left andRight)(Uper and Lower) 34 3.5 25

Others12 Front footboard bracket bolts (Left and Right) 34 3.5 2513 Rear footboard bracket bolts (Left and Right) 25 2.5 1814 Clutch master cylinder clamp bolts 11 1.1 97 in·lbEngineEngine Oil Drain Plugs:15 Engine oil drain plug 20 2.0 1516 Final gear case drain plug 8.8 0.90 78 in·lbCotter Pin or Circlip17 Rear axle nut cotter pin – – –18 Rear master cylinder cotter pin – – –19 Front footboard pin circlips (Left and Right) – – –20 Rear footboard pin circlips (Left and Right) – – –

AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.S: Tighten the upper clamp bolt first, and then the lower clamp bolt.

42 PREPARATION

Standard Torque TableThis table relating tightening torque to thread

diameter, lists the basic torque for bolts andnuts. Use this table for only the bolts and nutswhich do not require a specific torque value.All of the values are for use with dry solvent-cleaned threads.General Fasteners:Threads Torquedia. mm N·m kgf·m ft·lb

30 ~ 435 3.4~4.9 0.35~0.50

in·lb52 ~ 69

6 5.9~7.8 0.60~0.80in·lb

8 14~19 1.4~1.9 10.0~13.510 25~34 2.6~3.5 19.0~2512 44~61 4.5~6.2 33~4514 73~98 7.4~10.0 54~7216 115~155 11.5~16.0 83~11518 165~225 17.0~23.0 125~16520 225~325 23~33 165~240

Test Ride the Motorcycle•Complete the test ride checklist.

ControlCables:

Throttle control cables mustwork without binding in anysteering position.

Steering: Action is free fromlock-to-lock.

Suspension: Check operation front andrear.

Engine: Electric starter worksproperly and engine startspromptly. Good throttleresponse and return.

Transmission Smooth operation.and Clutch:Brakes: Adequate, smooth stopping

power, No drag.Speedometer: Check operationElectrical System:Headlight - check high and low beams.Taillight - check operation.Brake Light - check operationTurn Signal Lights - check operation.Horn - check operationInstrument Lights and Indicator Lights -Check operation.

Engine Stop Switch Works:Starter Interlock Switch Works:No Unusual Noises:No Fuel, Oil, Brake Fluid, Clutch Fluid,or Coolant Leaks:PREPARATION COMPLETE.

WARNINGNew tires are slippery and may causeloss of control and injury. A break-in pe-riod of 160 km (100 miles) is necessaryto establish normal tire traction.During break-in, avoid sudden andmaxi-mum braking and acceleration, and hardcornering.

A & P Check List•Complete the A & P Check List.

MODEL APPLICATIONYear Model Name

2005 VN1600–D1 VULCAN 1600 NOMADVN1600 CLASSIC TOURER

Part No. 99931-1445-01