VULCAN 1600 NOMAD
VN1600 CLASSIC TOURER
Motorcycle
Assembly & Preparation
Manual
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Table of Contents
Uncrating ......................................................................................
Opening Crate .............................................................................
Parts Check.................................................................................
Assembly ......................................................................................
Handlebar....................................................................................
Throttle Grip and Right Switch Housing ......................................
Front Brake Master Cylinder .......................................................
Left Switch Housing.....................................................................
3
3
4
8
8
8
9
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
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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.
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.
•
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. 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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4 UNCRATING
Parts Check
Open the parts box, and check the parts against the illustrations. There may be minor differences
between 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.
•
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UNCRATING 5
No.
1
Part Name
Qty
1
Remarks
Handlebar with Grip
Handlebar Clamp
Clamp Bolt, Socket
2
4
D = 10, L = 23
Plastic Plug, Clamp Bolt
Throttle Grip
4
Large
1
Clamp, Master Cylinder
2
Clamp Bolt, Master Cylinder, Socket
Plastic Plug, Clamp Bolt
Plastic Clamp, Wiring and Hose
Screw, Switch Housing, LH & RH
Rear View Mirror, LH & RH
Front Wheel
4
D = 6, L = 20
Small
4
4
L = 88.5
4
D = 5, L = 25
2
2
3
1
Axle Collar, LH & RH
2
L = 46.5
Front Fender with Brace
Socket Bolt, Front Fender
For US and CN Models
Brake Hose Clamp, LH & RH
Grommet, Brake Hose
1
4
D = 8, L = 35
2
2
2
2
Front Reflector, LH & RH
Flanged Nut, Reflector
D = 5
4
5
For other than US and CN Models
Brake Hose Clamp, LH & RH
Grommet, Brake Hose
2
2
1
2
2
2
1
1
1
2
2
2
2
2
4
4
2
2
1
1
1
1
4
4
4
Front Left Footboard Assembly
Flanged Bolt, Front Footboard, LH
Front Guard, LH & RH
D = 10, L = 30
D = 10, L = 25
Flanged Bolt, Front Guard
Warning Label, Front Left Guard
Front Shift Pedal
US and CN Models Only
Rear Shift Pedal
Flanged Bolt, Front and Rear Shift Pedals
Rear Guard, LH & RH
D = 8, L = 25
6
Flanged Bolt with Washer, Rear Guard, Upper
Socket Bolt, Rear Guard, Lower
Plastic Plug, Socket Bolt, Rear Guard
Flanged Bolt, Rear Guard
Cap Nut, Rear Guard
D = 8, L = 30
D = 10, L = 50
Large
D = 8, L = 35
D = 8
Helmet Lock
Located in the left side cover.
D = 5, L = 12
Screw with Non-permanent locking agent, Helmet Lock
Warning Label, Rear Left Guard
Backrest Pad
US and CN Models Only
7
Backrest Frame
Cover with Mark, Backrest
Cap Nut, Cover
D = 6
Bolt, Backrest Frame
D = 8, L = 50
D = 8
Nut, Backrest Frame
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6 UNCRATING
* :European Models Only
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UNCRATING 7
No.
8
Part Name
Horn with Bracket
Qty
1
Remarks
Flanged Bolt, Horn
1
9
License Plate Bracket
Bolt, Bracket, License Plate
Bracket, Reflector
1
2
1
D = 6, L = 12
(US)(CN)(AUS) only
(US)(CN) only
Reflector
3
Reflector
1
(AUS) only
Cap Nut, Reflector
Cap Nut, Reflector
3
1
4
2
4
2
1
D = 5, (US)(CN) only
D = 5, (AUS) only
D = 6, (US) only
D = 6, (CN)(AUS)(EUR) only
D = 6.5 × 20 × 1.6, (US) only
Cap Nut, Black, License Plate
Cap Nut, Black, License Plate
Flat Washer, Black, Holder, License Plate
Flat Washer, Black, Holder, License Plate
Holder, License Plate
D = 6.5 × 20 × 1.6, (CN) (AUS)(EUR) only
Bolt with Flat Washer
Bolt with Flat Washer
Cap Nut, Holder, License Plate
7
5
3
D = 6, L = 14 (US only)
D = 6, L = 14, (CN)(AUS)(EUR) only
D = 6
10 Windshield Assembly with
Center Plate, Outer & Inner
Damper, Center Plate, Outer & Inner
Socket Bolt with Washer, Center Plate
Cap Nut
1
(2)
(2)
(4) D = 6, L = 20
(10) D = 6
Vulcan Mark
(1) (US)(CN)(AUS) only
VN1600 Mark
(1) (EUR) only
Outer Plate, LH & RH
Inner Plate, LH & RH
Outer Damper, Outer Plate, LH & RH
Inner Damper, Inner Plate, LH & RH
(2)
(2)
(2)
(2)
Socket Bolt with Washer, Outer & Inner Plate (6) D = 6, L = 25
Sub-windshield
Stay, Windshield, LH & RH
Trim, Windshield
(1)
(2)
1
L = 1 900, (EUR) only
(EUR) only
Clamp, Trim
2
Socket Bolt, Stay
4
D = 8, L = 10
Bracket, Windshield, LH & RH
Socket Bolt, Bracket, Upper
Socket Bolt, Bracket, Lower
11 Outer Plate, Deflector, LH & RH
Deflector, LH & RH
2
2
2
2
D = 8, L = 20
D = 8, L = 25
2
Stay, LH & RH
2
Socket Bolt with Washer
Cap Nut
4
4
D = 6, L = 16
D = 6
Socket Bolt, Stay
4
D = 6, L = 16
12 Saddlebag, LH
1
Lock, Saddlebag
Damper, Bottom
1
2
Located in the left side cover.
Large
Damper, Upper
2
D = 12
Flanged Collar
2
2
4
1
D = 12, L = 13.1
D = 8, L = 75
D = 8.5 × 20, T = 1.6
Flanged Bolt, Saddlebag
Flat Washer, Saddlebag, Black
13 Battery Electrolyte, FTZ16-BS
14 Owner’s Manual
1
AUS: Australian Model
CN: CN Model
EUR: European Model
US: United States Model
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8 ASSEMBLY
Assembly
Handlebar
Throttle Grip and Right Switch
Housing
Alignment Pin Type
NOTE
Apply a light coat of grease on the exposed
•
•
żPosition the handlebar clamp on the handle-
portion of the throttle inner cables.
Fit both throttle cable tips into the nearest
bar with the slanted side facing rearward.
socket in the throttle grip.
Set the handlebar to match its punched mark
•
to the rear portion of the lower clamp mating
face and install the upper clamps and bolts (D
= 10, L = 23).
A. Front Half (Right Switch Housing)
B. Throttle Cable (Accelerator)
C. Cable Tips: Apply Grease.
D. Throttle Grip
E. Throttle Cable (Decelerator)
F. Rear Half (Right Switch Housing)
A. Front Bolts
B. Slanted Side
C. Gap
D. Punched Mark
E. No Gap
F. Forward
Fit the two halves of the right switch housing
so that the pin on the front half fits into the
hole in the handlebar.
•
Handlebar Clamp Bolt Tightening
Tighten the front clamp bolts first, and then
•
the rear clamp bolts to the specified torque.
There will be a gap at the rear part of the
clamp 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. Hole
B. Pin
C. Front Half
Insert the two screws (D = 5, L = 25) and
tighten them.
Tighten the holder screw.
Check that the throttle grip moves smoothly
from full open to close, and the throttle closes
quickly and completely.
•
•
•
A. Plastic Plugs
B. Handlebar Clamps
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ASSEMBLY 9
Push the small plastic plugs (2) into the mas-
ter cylinder clamp bolts.
•
A. Right Switch Housing
B. Screws (L = 25)
C. Harness
A. Plastic Plugs
B. Master Cylinder
D. Throttle Cable (Accelerator)
E. Throttle Cable (Decelerator)
F. Holder Screw
Left Switch Housing
Fit the two halves of the left switch housing
•
Front Brake Master Cylinder
together so that the vertical parting line of the
front and rear halves align with the punched
mark on the handlebar.
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 the
master cylinder clamp bolts.
Install the front master cylinder with its clamp
and the two socket bolts (D = 6, L = 20).
•
•
A. Punched Mark
B. Rear Half (Left Switch Housing)
C. Front Half
D. Screws (L = 25)
E. Harness
A. Front Master Cylinder
B. Punched Mark
C. Clamp
Insert the two screws (D = 5, L = 25) and
•
tighten them securely.
D. Socket Bolts
E. Harness
F. Front Brake Light Switch
G. Connectors and Dust Covers
Position the master cylinder so that the gap
•
between the front and rear master cylinder
clamps aligns with the punched mark on the
handlebar.
Tighten the upper clamp bolt first and then the
lower bolt to the specified torque.
•
Torque: 8.8 N·m (0.90 kgf·m, 78 in·lb)
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10 ASSEMBLY
Clutch Master Cylinder
Wiring Clamps
Apply silicone grease or PBC grease to the
master cylinder clamp bolts.
Install the clutch master cylinder with its
clamp and the two socket bolts (D = 6, L =
20).
Fasten the front brake hose and the right
switch housing harness to the right side of
the handlebar with two plastic clamps.
•
•
•
NOTE
żThe plastic clamp at the inside fastens the
Position the master cylinder so that the gap
•
right switch harness only.
between the front and rear master cylinder
clamps aligns with the punched mark on the
handlebar.
A. Handlebar (Right Side)
B. Plastic Clamps
C. Front Brake Hose
D. Right Switch Harness
A. Clamp
B. Clutch Master Cylinder
C. Punched Mark
D. Connector and Dust Cover
E. Starter Lock-out Switch
F. Harness
Fasten the clutch hose and the left switch
housing harness to the left side of the han-
dlebar with two plastic clamps.
•
G. Socket Bolts
Connect the connector of the left switch hous-
ing to the starter lock-out switch on the master
cylinder.
•
Tighten the upper clamp bolt first and then the
lower bolt to the specified torque.
•
Torque: 11 N·m (1.1 kgf·m, 97 in·lb)
Push the small plastic plugs (2) into the clutch
master cylinder clamp bolts.
•
A. Handlebar (Left Side)
B. Plastic Clamps
C. Clutch Hose
D. Left Switch Harness
A. Plastic Plugs
B. Clutch Master Cylinder
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ASSEMBLY 11
A. Left Switch Lead
B. Clutch Hose
C. 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 Cables
G. Brake Hose
H. Right Switch Lead
I. Handlebar
Front Fender
Front Reflectors (for US and CN Models
only)
Assemble the front left and right reflectors and
the brake hose clamps with the nut (D = 5) on
each.
•
A. Front Brake Hose Clamp (Left)
B. Front Brake Hose Clamp (Right)
C. Front Reflectors
D. Nuts
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12 ASSEMBLY
Front Fender Installation
US and CN Models
Lift the motorcycle off the crate base and sup-
•
port the motorcycle with a suitable stand or
jack.
Loosen the axle clamp bolts on the right fork
leg and remove the front axle.
Loosen the two flanged bolts (D = 10, L = 47)
to remove each front brake caliper.
•
•
A. Front Fender
B. Bolts (D = 8, L = 35)
C. Brake Hose Clamp (Left)
Other than US and CN Models
A. Front Brake Calipers
B. Flanged Bolts (D = 10, L = 47)
CAUTION
Do not leave the calipers hanging by
the brake hoses. After removing the
calipers, secure them to the frame using
a suitable band.
Install the front fender with its more rounded
end facing forward.
•
A. Front Fender
B. Bolts (D = 8, L = 35)
C. Brake Hose Clamp (Left)
Front Wheel Installation
Check the wheel rotation mark on the front
tire.
•
NOTE
żThe direction of the wheel rotation is shown
by an arrow on the front tire. Install the wheel
so that the rotation mark coincides with wheel
rotational direction.
A. Front Fender
B. Forward
Install the front fender on the fork legs, and in-
•
stall the front left and right brake hose clamps
on the inside of the fender with the four bolts
(D = 8, L = 35) and tighten them.
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ASSEMBLY 13
A. Front Tire
B. Arrow
A. Pump the fork up and down.
B. Block
C. Rotation
Tighten the axle clamp bolts on the right fork
leg to the specified torque.
•
Fit the axle collars on both sides of the front
•
•
•
Torque : 29 N·m (3.0 kgf·m, 21 ft·lb)
wheel hub. The collars are identical.
Put the front wheel assembly between the
fork legs.
NOTE
Insert the front axle from the right side of the
wheel and push it completely through.
żTighten the two front axle clamp bolts alter-
nately two times to ensure even tightening
torque.
Check the clearance between the right fork
•
leg and the axle collar with a thickness gauge.
There should be about 2.0 mm (0.08 in.) of
clearance. The clearance between 1.05 ~
3.19 mm (0.04 ~ 0.13 in.) is acceptable.
A. Front Axle
B. Collar (Right)
C. Axle Clamp Bolts (Right)
D. Collar (Left)
Tighten the front axle to the specified torque.
•
A. Right Fork Leg
B. Front Axle
Torque : 108 N·m (11.0 kgf·m, 80 ft·lb)
Temporary install the front brake calipers.
Before tightening the axle clamp bolts on the
right fork leg, pump the front fork up and down
4 or 5 times to align the right front fork leg and
to seat the front axle. Do not pull the brake
lever when pumping the fork.
•
C. Axle Clamp Bolts
D. About 2.0 mm (0.08 in.)
E. Collar (Right)
•
If the clearance is out of this range, remove
the front wheel and check the axle, wheel hub
and other related parts for damage.
•
NOTE
żDo not apply the front brake during this
process to stop the motorcycle from rolling
forward. Put a block in front of the front wheel
to prevent movement.
Tighten both front brake caliper mounting
bolts (D = 10, L = 47) to the specified torque.
•
Torque : 34 N·m (3.5 kgf·m, 25 ft·lb)
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14 ASSEMBLY
Check the front brake.
Other than US and CN Models
•
A. Front Brake Hose (Left)
B. Grommet
A. Front Brake Caliper (Left)
B. Bolts (D = 10, L = 47)
C. Brake Hose Clamp (Left)
WARNING
Do not attempt to ride the motorcycle un-
til a full brake lever is obtained by pump-
ing the brake lever until the pads are
against the disc. The brake will not func-
tion on the first application of the lever if
this is not done.
Front and Rear Shift Pedals
NOTE
żInstall the front and rear shift pedals after the
“Clutch Fluid” section in the Preparation chap-
ter.
Install the front shift pedal on the shift shaft
aligning the punched marks on the pedal and
the shaft.
Install the pedal bolt (D = 8, L = 25) and
tighten it to the specified torque.
•
Front Brake Hose Grommets
Fit the grommet onto each front left and right
brake hose, and install it in the clamp.
•
•
US and CN Models
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 shift
pedal.
•
A. Front Brake Hose (Left)
B. Grommet
C. Brake Hose Clamp (Left)
A. Front Shift Pedal
B. Bolt (D = 8, L = 25)
C. Align the Punched Marks.
D. Rear Shift Pedal
E. Shift Shaft
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ASSEMBLY 15
Install both front left and right guards on the
frame with the upper mounting bolts (D = 10,
L = 25), and on the front footboard brackets
with the lower mounting bolts (D = 10, L = 30).
•
Front Footboard (Left)
NOTE
żInstall the left footboard after the “Clutch Fluid”
section in the Preparation chapter.
Install the left footboard assembly on the
frame with one bolt (D = 10, L = 30) at the
rear and tighten it.
•
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 guard
mounting bolts to the specified torque.
•
A. Front Footboard (Left)
B. Bolt (Rear)
Torque : 34 N·m (3.5 kgf·m, 25 ft·lb)
Label Installation (for US and CN Mod-
els only)
NOTE
żThe bolt in front is for tightening the footboard
Wipe off any oil or grease from the application
•
•
żaTnigdhttehne tfhroenftrognutafrodottobgoeatrhdemr.ounting bolts af-
ter installing the front guards to the specified
torque.
area.
Peel the warning label off the backing sheet
and stick it on the center of the front left guard.
Front Guards (Left and Right)
Front Guards Installation
Remove the front side mounting bolt from the
front right footboard.
•
A. Front Guard (Left)
B. Label For US Models (56070-1285)
C. Label Top
D. Label For CN Models (56070-1180)
A. Front Footboard (Right)
B. Bolt
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16 ASSEMBLY
Helmet Locks
Unlock the helmet lock with the key and fit
•
the small projection of the lock into the hole
in the bracket of each rear guard and fasten
it with the screw (D = 5, L = 12) having a
non-permanent locking agent.
Lock the helmet lock.
•
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 socket
bolt (D = 10, L = 50) and tighten them.
•
A. Helmet Lock
B. Ignition Key
C. Projection
D. Screw
E. Rear Guard (Left)
Rear Guards (Left and Right)
Rear Guards Installation
Remove the right saddlebag.
Insert the ignition key into the lock and turn
the key counterclockwise and pull the knob
outward to open the lid.
•
•
A. Rear Guard (Left)
B. Bolts (D = 8, L = 35) and Cap Nuts
C. Bolt (D = 10, L = 30)
D. Socket Bolt (D = 10, L = 50)
Push the large plastic plug into the top of the
socket bolt.
•
A. Saddlebag (Right)
B. Ignition Key
C. Counterclockwise
D. Knob
A. Plastic Plug
B. Rear Guard (Left)
Open the saddlebag lid and remove the bolts
(D = 8, L = 75) inside the saddlebag, and then
pull it up.
•
Install the right guard in the same manner as
the left guard.
•
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ASSEMBLY 17
Label Installation (for US and CN Mod-
els only)
Install the backrest between the brackets with
the flanged bolts (D = 8, L = 50)(4) and the cap
nuts (D = 8).
•
•
Wipe off any oil or grease from the application
•
•
area.
Tighten all the bolts and nuts securely.
Peel the warning label off the backing sheet
and stick it on the rear left guard.
A. Backrest
B. Cap Nuts (D = 8)
C. Bolts (D = 8, L = 50)
A. Rear Guard (Left)
B. Label For US Models (56070-1285)
C. Label Top
D. 20 mm (0.8 in.)
E. Label For CN Models (56070-1180)
Horn
Connect the horn lead connectors (BK, BK)
•
of the harness to the horn terminals at the left
side of the radiator.
NOTE
żReinstall the right saddlebag after the “Rear
Brake 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 cover
with the cap nuts (D = 6)(4).
•
A. Horn
B. Connectors (BK, BK)
C. Bracket
Install the horn with bracket to the frame with
the bolt (D = 8, L = 12) and tighten it.
•
A. Backrest Pad
B. Cover
C. Cap Nut (D = 6)
D. Frame
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18 ASSEMBLY
A. Horn
A. Locknut
B. Bolt (D = 8, L = 12)
C. Bracket
B. Rear View Mirror (Left)
Installation and adjustment of the right side
mirror is common with the left side. Follow
the procedure specified for the left side.
•
Choke Knob
Turning Stay Type
Loosen the locknut and fasten the choke knob
to the bracket with locknut.
•
Screw the mounting area of the left rear view
•
mirror into the holder all the way, and tighten
the lower hexagonal area securely.
A. Choke Knob
B. Locknut
C. Bracket
A. Lower Hexagonal Area for Tightening
B. Upper Hexagonal Area (Adapter)
C. Rear View Mirror (Left)
Rear View Mirrors (Left and Right)
Conventional Type (Single Nut)
CAUTION
Loosen the locknut completely.
Screw the rear view mirror in completely, and
then back it two turns out.
Turn the mirror stay to assure visibility to the
rear with the operator sitting on the motorcy-
cle and tighten the locknut securely.
Do not force to tighten and/or loosen the
upper hexagonal area (adapter) with a
spanner or wrench. Disassembly of this
area is not possible. Non-permanent
locking agent is already applied to the
threads of this inner area. Forcible loos-
ening may damage the adapter and/or
the turning mechanism of the stay.
•
•
•
Adjust the rear view mirror by slightly moving
only the mirror portion of the assembly.
•
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ASSEMBLY 19
A. Lower Hexagonal Area for Tightening
B. Upper Hexagonal Area (Adapter)
C. Stay
A. Windshield Assembly
Remove the dummy bolts on the fork cover
and discard them.
•
D. Non-permanent Locking Agent applied.
Turn the stay to assure visibility to the rear
•
•
with the operator sitting on the motorcycle.
Adjust the rear view mirror by slightly moving
only the mirror portion of the assembly.
A. Fork Cover
B. Dummy Bolts (Right Side)
Install the left and right mounting brackets on
the fork cover with the socket bolts (D = 8, L
= 20)(D = 8, L = 25).
•
A. Stay
B. Mirror
Installation and adjustment of the right side
mirror is common with the left side. Follow
the procedure specified for the left side.
•
Windshield
CAUTION
Be sure not to damage the surface of the
windshield when installing or handling.
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 and
tighten the bolts securely.
•
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20 ASSEMBLY
Install each deflector on the bracket with the
socket bolts (D = 8, L = 10)(2) for each side
and tighten them.
•
A. Windshield Assembly
B. Socket Bolts (D = 8, L = 10)
Trim Installation [EUR Models Only]
A. Deflector (Right)
B. Socket Bolts (D = 8, L = 10)
Fit the windshield trim onto the edge of the
•
windshield starting from each lower edge.
Fix the trim ends with the clamps (2).
•
Windshield Height Adjustment
The windshield can be adjusted 50 mm (2 in.)
in height to suit the rider’s preference.
Loosen both the upper and lower bolts on
each lower side of the windshield and move
it up or down.
•
Align both the left and right windshield stays.
Tighten the bolts securely.
•
•
A. Trim
B. 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. Windshield
B. Bolts
C. Positioning Marks
Sub-windshield Adjustment
Loosen the windshield bolts on the left and
•
right vertical outer plates and move the sub
-windshield up or down. The distance should
be 10 mm (0.04 in.) between the lower edge
of the sub-windshield and the headlight body.
Tighten the windshield bolts.
•
A. Stay (Left)
B. Deflector
C. Outer Plate
D. Socket Bolts (D = 6, L = 16)
E. Stay (Right)
F. Cap Nuts
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ASSEMBLY 21
A. Reflectors
A. Bolts
B. Reflector Bracket
C. License Plate Holder
D. Cap Nuts (D = 5)
B. Sub-windshield
Install the license plate holder and the rear
reflector bracket on the license plate bracket
with the bolts (D = 6, L = 14)(3) and plated
cap nuts (3) and tighten them. The remaining
fasteners are used for the license plate.
License Plate Bracket
•
License Plate Bracket Installation
Install the license plate bracket onto the rear
fender with the bolts (D = 6, L = 12)(2).
•
A. Rear Fender
B. License Plate Bracket
C. Bolts (D = 6, L = 12)
A. License Plate Holder
B. Reflector Bracket
C. Bolt (D = 6, L = 14)
D. Cap Nut
E. License Plate Bracket
F. For US Models
G. For CN Models
Rear Reflectors and License Plate
Holder
AUS Models only
Install the rear reflector on the license plate
holder with the cap nut (D = 5) and tighten it.
US and CN Models only
•
Assemble the rear reflectors, bracket, and li-
•
cense plate holder with the cap nut (D = 5) on
each.
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22 ASSEMBLY
A. Reflector
B. License Plate Holder
C. Cap Nut (D = 5)
A. License Plate Holder
B. Bolt (D = 6, L = 14)
C. Cap Nut
D. License Plate Bracket
Install the license plate holder on the license
•
plate bracket with the bolts (D = 6, L = 14)(3)
and plated cap nuts (3) and tighten them. The
remaining fasteners are used for the license
plate.
Left Saddlebag
NOTE
żInstall the saddlebags after the “Final Gear
Case Oil”, “Rear Brake Fluid”, and “Rear
Shock Absorber” sections in the Preparation
chapter.
Left Saddlebag Lid Lock Installation
NOTE
żAfter the saddlebag is installed, you can install
the left saddlebag lid lock.
Inspect the saddlebags for damage.
Insert the ignition key into the lock, and turn
the key counterclockwise to the unlocked po-
sition (hook faces left).
•
•
A. License Plate Holder
B. Bolt (D = 6, L = 14)
C. Cap Nut
With the locked-position mark on the lock fac-
•
D. License Plate Bracket
ing up (toward the handle), insert the hook
of the lock, then the lock into the hole in the
left saddlebag lid, and push it straight ahead
so that the projections on the lock fit into the
notches
Other than US, CN, and AUS Models
only
Install the license plate holder on the license
•
plate bracket with the bolts (D = 6, L = 14)(3)
and plated cap nuts (3) and tighten them. The
remaining fasteners are used for the license
plate.
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ASSEMBLY 23
Open the saddlebag lid, and insert the upper
dampers (2) into the holes in the saddlebag.
Push the flanged collars (2) into the damper.
•
•
A. Lock
B. Left Saddlebag
C. Locked-position Mark
D. Projections
E. Notches
A. Upper Damper
B. Collars
NOTE
Left Saddlebag Installation
żPush the lid lock all the way into the hole in
the lid so that the projection ends are inserted
into it.
NOTE
żOnly use the flat washers (T = 1.6 mm) (4)
to adjust the clearance [1.0 mm (0.04 in.) or
more] between the saddlebag upper dampers
and the bracket, as needed.
While aligning the protrusions on the bottom
•
of the saddlebag with the holes in the lower
bracket, engage the hook on the back of the
saddlebag with the upper bracket, then push
it down.
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 the
grooves fit into the holes in the lower brack-
ets of the left saddlebag/muffler bracket.
•
A. Saddlebag
B. Protrusion
C. Hook
D. Upper Bracket
A. Dampers
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24 PREPARATION
Measure the clearances between both the
After the saddlebag is installed, open and
close the lid several times, and check for
smooth movement of the lid handle and lid
lock 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.
•
•
•
front and rear upper dampers and the up-
per mounting bracket with the saddlebag
lightly pushed by hand against the mounting
bracket.
If the clearance is 1.0 mm (0.04 in.) or more
•
at the front and/or rear, adjust it. Insert one or
two flat washer(s) between the upper damper
and the mounting bracket until it is less than
1.0 mm (0.04 in.) at the front and/or rear.
Brake Disc Cleaning
Clean the front and rear brake discs using
oilless solvent.
•
WARNING
If not removed, the anticorrosive treat-
ment applied to the brake disc surface
will interfere with brake action, and an
unsafe riding condition could result.
A. Saddlebag
B. Top Stay
C. Upper Bracket
D. Upper Dampers
E. Clearance
F. Flat Washer
G. Bolts
If the clearance is less than 1.0 mm (0.04
in.) at the front and/or rear, the flat washer
is unnecessary.
•
Preparation
Battery Service
Open the saddlebag lid and install the flanged
•
bolts (D = 8, L = 75)(2), (through the flat
washer(s) if necessary) and tighten them se-
curely.
The battery used in this motorcycle is a sealed
type and never needs to be refilled. Follow the
procedure for activating a new battery to ensure
the 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.
CAUTION
Incorrect Battery Activation will reduce
battery performance and service life. Be
sure to strictly follow the Battery Service
instructions in this Manual.
A. Left Saddlebag
B. Bolts (D = 8, L = 75)
Make sure to use the electrolyte packed in the
crate with the unit.
Make sure that the model name of the elec-
trolyte container matches the model name of
the battery. These names must be the same.
•
•
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PREPARATION 25
Battery Model Name for
VN1600–D1: FTZ16–BS
A. Rider’s Seat
B. Bolt (D = 6, L = 14)
A. Model Name of the Electrolyte
B. Model Name of the Battery
Remove the screw (D = 6, L = 14) and pull
the right side cover outward to clear the pro-
jections.
•
CAUTION
Sealed battery electrolyte has a higher
concentration of sulfuric acid. Each
container contains the proper amount
of electrolyte for its specific battery.
Insufficient or incorrect electrolyte will
reduce battery performance and service
life. Electrolyte over capacity can lead
to battery cracking or leaking and result
in corrosion damage to the vehicle.
Riders Seat Removal
Remove the bolt (D = 6, L = 14) and pull the
passenger’s seat rearward.
•
A. Right Side Cover
B. 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 P
connectors.
Disconnect the 6 P connector and remove
the black diagnosis 4 P connector from the
holder, and then unfasten the plastic clamp
on the bottom of the battery holder while lift-
ing the holder.
•
•
A. Bolt (D = 6, L = 14)
B. Passenger’s Seat
Remove the bolt (D = 6, L = 14) and pull the
rider’s seat rearward.
•
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26 PREPARATION
Battery Activation
Filling the Battery with Electrolyte
CAUTION
Do not remove the aluminum sealing
sheet [A] from the filler ports [B] until
just prior to use. Be sure to use the ded-
icated electrolyte container for correct
electrolyte volume.
Place the battery on a level surface.
Check to see that the sealing sheet [A] has no
peeling, tears, or holes in it.
Remove the sealing sheet [A].
•
•
A. Wiring Clamp
B. 1 P Connector (Negative Lead)
C. 2 P Connector
•
NOTE
D. 3 P Connector
E. Battery Holder Nuts
F. Battery Holder
żThe battery is vacuum sealed. If the sealing
sheet has leaked air into the battery, it may
require a longer initial charge.
G. Battery
H. 6 P Connector (Rear Harness)
I. 4 P Connector (Diagnosis)
J. Plastic Clamp
K. 15 A Fuse Holder
L. Harness (Fuel Pump)
M. Harness (Fuel Gauge)
Remove the 15 A fuse holder from the battery
holder, then remove the battery holder.
•
Remove the electrolyte container from the
vinyl bag.
Detach the strip of caps [A] from the container
and set aside, these will be used later to seal
the battery.
•
•
NOTE
żDo not pierce or otherwise open the sealed
cells [B] of the electrolyte container. Do not
attempt to separate individual cells.
A. Battery Holder
B. 15 A Fuse Holder
C. Projection
D. Screwdriver
Take the battery out of the battery case.
Clean the terminals.
•
•
Battery Specifications
Make
Furukawa
FTZ16-BS
12 V 18 Ah
0.82 L
Battery Type
Battery Capacity
Electrolyte Capacity
Battery/Electrolyte Set P/No.
26012-1371
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PREPARATION 27
Place the electrolyte container upside down
with the six sealed cells into the filler ports
of the battery. Hold the container level, push
down to break the seals of all six cells. You
will see air bubbles rising into each cell as the
ports fill.
NOTE
•
żCharging the battery immediately after filling
can shorten service life. Let the battery sit for
at least 60 minutes after filling.
Initial Charge
Place the strip of caps loosely over the filler
•
NOTE
ports.
żDo not tilt the electrolyte container.
A. Strip
Check the electrolyte flow.
If no air bubbles [A] are coming up from the
filler ports, or if the container cells have not
emptied completely, tap the container [B] a
few times.
•
Newly activated sealed batteries require an
initial charge.
Standard Charge 1.8 A × 5 a 10 hours
•
•
If using a recommended battery charger, fol-
low the charger’s instructions for newly acti-
vated sealed battery.
•
Kawasaki-recommended chargers:
Optimate III
Yuasa 1.5 Amp Automatic Charger
Battery Mate 150–9
If the above chargers are not available, use
equivalent one.
•
NOTE
żCharging rates will vary depending on how
long the battery has been stored, tempera-
ture, and the type of charger used. Let battery
sit 60 minutes after initial charge, then check
voltage using a voltmeter. If it is not at least
12.6 volts, repeat charging cycle.
Keep the container in place for 20 minutes or
•
more. Don’t remove the container from the
battery until it’s empty, the battery requires all
the electrolyte from the container for proper
operation.
CAUTION
After charging is completed, press down
•
Removal of the container before it is
completely empty can shorten the ser-
vice life of the battery. Do not remove
the electrolyte container until it is com-
pletely empty and 20 minutes have
elapsed.
firmly with both hands to seat the strip of
caps [A] into the battery (don’t pound or ham-
mer). When properly installed, the strip of
caps will be level with the top of the battery.
Gently remove the container from the battery.
Let the battery sit for 60 minutes prior to
charging to allow the electrolyte to permeate
into the plates for optimum performance.
•
•
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28 PREPARATION
Pull the battery positive cable (+) downward
and through the guide in the right side of the
battery case, and then route the cable as
shown.
Reinstall the 15 A fuse holder and the battery
holder, and then install the black diagnosis 4
P connector on the holder and connect the 6
P connector, and fasten the harness with the
plastic clamp.
•
•
CAUTION
Once the strip of caps [A] is installed
onto the battery, never remove the caps,
nor add water or electrolyte to the bat-
tery.
NOTE
żTo ensure maximum battery life and customer
satisfaction, it is recommended the battery be
load tested at three times its amp-hour rating
for 15 seconds.
Re-check voltage and if less than 12.6 volts
repeat the charging cycle and load test. If still
below 12.6 volts the battery is defective.
A.
Pull the Positive Cable (+) downward.
B. Positive Cable (+)
C. Battery
D. 4 P Connector (Diagnosis)
E. 6 P Connector (Rear Harness)
F. 15 A Fuse Holder
G. Wiring Clamp
H. 3 P Connector
I. 2 P Connector
J. 1 P Connector (Negative Lead)
K. Negative Cable (–)
Battery Installation
Turn the ignition switch OFF.
Place the battery into the battery case.
•
•
Connect the 1 P, 2 P, and 3 P connectors,
•
and fasten the harness of the 2 P and 3 P
connectors with the wiring clamp.
First connect the red capped positive cable
(+) to the positive terminal, and then connect
the negative cable (–) to the negative termi-
nal.
•
Put a light coat of grease on the terminals to
prevent corrosion.
Cover the (+) terminal with its protective cap,
and install the battery holder nuts and tighten
them.
•
•
A. Negative Cable (–)
B. Positive Cable (+)
C. Battery Holder
NOTE
żInstall the right side cover after the “Coolant”
section in the Preparation chapter.
D. Plastic Clamp
E. Battery
F. 15 A Fuse Holder
G. Run the positive cable (+) through
the guide in the right side of the
battery case.
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PREPARATION 29
Viewed from Right
Rider’s Seat Installation
•
Insert the projection at the front of the rider’s
seat into the receptacle on the frame.
A. Positive Terminal (+)
B. Battery
C. Positive Cable (+)
D. ECU Relay
E. Negative Cable (–)
A. Projection
B. Receptacle
Install the bolt (D = 6, L = 14) and tighten it.
•
Viewed from Top
A. Rider’s Seat
B. Bolt (D = 6, L = 14)
Insert the projection at the front of the passen-
ger’s seat into the receptacle on the frame.
•
A. Negative Cable (–)
B. Run the Positive Cable (+) through
the Guide in the Battery Case.
C. Positive Cable (+)
A. Receptacle
B. Projection
D. Battery
E. 4 P Connector (Diagnosis)
F. 6 P Connector (Rear Harness)
G. Plastic Clamp
H. 15 A Fuse Holder
I. ECU Connector
J. 3 Connectors (1 P, 2 P, 3 P)
Install the bolt (D = 6, L = 14) and tighten it.
•
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30 PREPARATION
A. Bolt (D = 6, L = 14)
B. Passenger’s Seat
A. Front Brake Fluid Reservoir
B. Upper Level Line
WARNING
Front Brake Fluid
Never reuse old brake fluid.
Do not use fluid from a container that
has been left unsealed or that has been
open for a long time.
Do not mix two types of fluid for use in
the brakes. This lowers the brake fluid
boiling point and could reduce brake ef-
fectiveness. It may also cause the rub-
ber brake parts to deteriorate.
Front Brake Fluid Level Inspection
With the front brake fluid reservoir held hori-
•
zontal, check that the fluid level is above the
lower level line.
Don’t leave the reservoir cap off for any
length of time to prevent moisture con-
tamination of the fluid.
Don’t add or change brake fluid in the
rain or during conditions of blowing dust
or debris.
CAUTION
Brake fluid quickly ruins painted sur-
faces. Wipe up any spilled fluid immedi-
ately.
A. Front Brake Fluid Reservoir
B. Lower Level Line
If the fluid level in the reservoir is lower than
the lower level line, check for fluid leaks in the
front brake lines and fill the reservoir.
•
Operate the brake lever several times.
If it feels spongy, there might be air in the
brake line.
If necessary, bleed the air in the front brake
lines.
Also check for fluid leakage around the fit-
tings.
•
•
•
•
Loosen the screws to remove the front brake
fluid reservoir cap and diaphragm.
Fill the reservoir to the upper level line with
DOT4 brake fluid. Inside the front brake
reservoir is a stepped line showing the upper
level line.
•
•
Front Brake Line Air Bleeding
Remove the reservoir cap and diaphragm,
and check that there is plenty of fluid in the
reservoir.
•
NOTE
żThe fluid level must be checked several times,
during the bleeding operation and replenished
as necessary. If the fluid in the reservoir runs
completely out any time during bleeding, the
bleeding operation must be repeated from the
beginning since air will have entered the line.
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PREPARATION 31
Attach a clear plastic hose to the bleed valve
on each front brake caliper and run the other
end of the hose into a container.
With the reservoir cap off, slowly pump the
brake lever several times until no air bubbles
can be seen rising up through the fluid from
the holes at the bottom of the reservoir. This
bleeds the air from the brake master cylinder
end of the line.
•
•
Pump the brake lever a few times until it
becomes hard and then, holding the lever
squeezed, quickly open (turn counterclock-
wise) and close the bleed valve. Then release
the lever. Repeat this operation until no more
air can be seen coming out into the plastic
hose.
•
A. Rear Brake Fluid Reservoir
B. Cover
C. Upper Level Line
D. Lower Level Line
If the fluid level in the reservoir is lower than
•
the lower level line, check for fluid leaks in the
brake line, and fill the reservoir.
Loosen the bolt to remove the cover from the
reservoir.
Remove the reservoir cap and diaphragm,
and fill the reservoir to the upper level line with
DOT4 brake fluid.
•
•
CAUTION
Brake fluid quickly ruins painted sur-
faces. Wipe up any spilled fluid immedi-
ately.
A. Hold the brake lever applied.
B. Quickly open and close the bleed
valve.
NOTE
C. Release the brake lever.
żFirst, tighten the rear brake fluid reservoir cap
clockwise by hand until slight resistance is felt
indicating that the cap seated on the reser-
voir body, then tighten the cap an additional
1/6 turn while holding the brake fluid reservoir
body.
Repeat the previous step one more time for
the other front disc brake.
•
When air bleeding is finished, check that the
fluid level is between the upper and lower
level lines.
•
Install the diaphragm and reservoir cap.
Tighten the bleed valve(s) to the specified
torque.
•
•
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 Fluid
Rear Brake Fluid Level Inspection
With the rear brake fluid reservoir held hor-
izontal, check that the fluid level is between
the upper and lower level lines.
•
A. Reservoir
B. Cap
C. Clockwise
D. 1/6 turn
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32 PREPARATION
Operate the brake lever several times.
If it feels spongy, there might be air in the
brake line.
If necessary, bleed the air in the rear brake
line.
Also check for fluid leakage around the fit-
tings.
When air bleeding is finished, check that the
fluid level is between the upper and lower
level lines.
Tighten the bleed valve(s) to the specified
torque.
•
•
•
•
•
•
Torque: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Install the diaphragm and reservoir cap.
•
Rear Brake Line Air Bleeding
Remove the rear brake reservoir cap and di-
aphragm, and check that there is plenty of
fluid in the reservoir.
NOTE
•
żFirst, tighten the rear brake fluid reservoir cap
clockwise by hand until slight resistance is felt
indicating that the cap seated on the reser-
voir body, then tighten the cap an additional
1/6 turn while holding the brake fluid reservoir
body.
NOTE
żThe fluid level must be checked several times,
during the bleeding operation and replenished
as necessary. If the fluid in the reservoir runs
completely out any time during bleeding, the
bleeding operation must be repeated from the
beginning since air will have entered the line.
Apply the brake forcefully for a few seconds,
and check for fluid leakage around the fittings.
Install the cover with the bolt.
•
•
Attach a clear plastic hose to the bleed valve
on the rear brake caliper and run the other
end of the hose into a container.
•
Clutch Fluid
Clutch Fluid Level Inspection
With the reservoir cap off, slowly pump the
•
With the clutch reservoir held horizontal,
brake pedal several times until no air bub-
bles can be seen rising up through the fluid
from the holes at the bottom of the reservoir.
This bleeds the air from the rear brake master
cylinder end of the line.
•
check that the fluid level is above the lower
level line.
Pump the brake pedal a few times until it
•
becomes hard and then, holding the pedal
pushed down, quickly open (turn counter-
clockwise) and close the bleed valve. Then
release the pedal. Repeat this operation until
no more air can be seen coming out into the
plastic hose.
A. Clutch Fluid Reservoir
B. Lower Level Line
If the fluid level in the reservoir is lower than
the lower level line, check for fluid leaks in the
clutch line and fill the reservoir.
•
NOTE
żSince the clutch fluid is the same as the brake
fluid, refer to the “Front or Rear Brake Fluid”
section for further details.
A. Hold the brake pedal applied.
B. Quickly open and close the bleed
valve.
Loosen the screws to remove the clutch fluid
reservoir cap and diaphragm.
Fill the reservoir to the upper level line with
•
•
C. Release the brake pedal.
DOT4 clutch fluid. Inside the clutch reservoir
is a stepped line showing the upper level line.
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PREPARATION 33
Attach a clear plastic hose to the bleed valve
on the clutch slave cylinder and run the other
end of the hose into a container.
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 reservoir. This
bleeds the air from the clutch master cylinder
end of the line.
•
•
Pump the clutch lever a few times until it
becomes hard and then, holding the lever
squeezed, quickly open (turn counterclock-
wise) and close the bleed valve.
Then release the lever. Repeat this operation
until no more air can be seen coming out into
the plastic hose.
•
A. Clutch Fluid Reservoir
B. 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. 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 the
fluid level is between the upper and lower
level lines.
•
A. Alternator Outer Cover
B. Socket Bolts and Washers
Install the diaphragm and reservoir cap.
Tighten the bleed valve to the specified
torque.
•
•
Remove the reservoir cap and diaphragm,
and check that there is plenty of fluid in the
reservoir.
•
Torque: 7.8 N·m (0.80 kgf·m, 69 in·lb)
Apply the clutch forcefully for a few seconds,
•
•
NOTE
and check for fluid leakage around the fittings.
Apply a soap and water solution or rubber
lubricant to the body of the alternator cover
bolts for easy installation.
Reinstall the alternator outer cover with the
bolts and washers and tighten the bolts to the
specified torque.
żThe fluid level must be checked several times
during the bleeding operation and replenished
as necessary. If the fluid in the reservoir runs
completely out any time during bleeding, the
bleeding operation must be repeated from the
beginning since air will have entered the line.
•
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.
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34 PREPARATION
Rear Shock Absorber
Air Pressure Adjustment
STD Air pressure: Atmospheric
Rebound Damping Force Adjustment
Check the position of the rebound damping
•
force adjuster at the upper end of each rear
shock absorber. It has four positions. The
numbers on the adjuster show the setting po-
sition.
A. Tire Air Pressure Gauge
STD Rebound Damping Force:
No. 2 position
Fuel
WARNING
Fill the tank in a well-ventilated area, and
take ample care that there are no sparks
or open flames anywhere near the work
area.
Open the fuel tank cap, and check for debris
in the fuel tank.
Fill the fuel tank with one gallon or four liters
of unleaded gasoline. Use a gasoline with a
minimum Antiknock Index rating according to
the recommendation of your country. Refer to
the following table.
•
•
A. Air Valve
B. Rebound Damping Force Adjuster
C. Number
The antiknock index is an average of the Re-
search Octane Number (RON) and the Motor
Octane Number (MON), as shown in the table.
Turn the rebound damping force adjuster to
the No. 2 position.
•
Minimum
Octane Rating Method
Rating
Tire Air Pressures
To prevent flat-spotting during shipment, the
•
Antiknock
Index
(RON + MON)
2
90
95
tires are over-inflated before crating. Adjust
the pressures to the specified values in the
front and rear, and make sure to tighten the
caps securely.
Research Octane Number
(RON)
Tire Air Pressure [when cold]:
Close the fuel tank cap, and check for any
leaks.
•
Front:
Rear:
225 kPa (2.25 kgf/cm², 32 psi)
280 kPa (2.80 kgf/cm², 40 psi)
Coolant
Coolant Level Inspection
Situate the motorcycle so that it is perpendic-
ular to the ground.
Check the coolant level through the coolant
level gauge. The coolant level should be be-
tween the F (Full) and L (Low) marks.
•
•
NOTE
żCheck the level when the engine is cold (room
or atmospheric temperature).
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PREPARATION 35
NOTE
żA permanent type of antifreeze is installed in
the cooling system when shipped. It is col-
ored green and contains ethylene glycol. It is
mixed at 50 % and has the freezing point of –
35°C (– 31°F).
Engine Oil (4-stroke)
Engine Oil Level Inspection
NOTE
A. F (Full) Mark
żThis vehicle’s engine is filled with 10W-40 oil
from the factory. DO NOT DRAIN and refill
the crankcase before use. Check oil level and
drain plug tightness.
B. L (Low) Mark
C. Right Side Cover
Coolant Filling
If the amount of coolant is insufficient, remove
•
Engine Oil Drain Plug Torque:
20 N·m (2.0 kgf·m, 14 ft·lb)
the right side cover, pull open the cap from the
reserve tank and add coolant through the filler
opening to the F (Full) mark.
A. Oil Drain Plug
A. Cap
B. F (Full) Mark
C. L (Low) Mark
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 oil
level sight gauge in the lower right side of the
engine.
•
•
Install the cap.
To install the right side cover, insert the pro-
jections into the grommets.
Tighten the screw.
•
•
•
•
CAUTION
If the engine is run without oil, it will be
severely damaged.
Start the engine and run it for several minutes
at 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 the
H (High) and L (Low) level lines next to the
gauge.
A. Right Side Cover
B. Projections
C. Grommets
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36 PREPARATION
Final Gear Case Oil
Final Gear Case Oil Level Inspection
Have a helper hold the motorcycle vertical on
level ground.
Remove the filler cap.
Check the oil level. If it is low, add oil as
necessary. The oil level should come to the
bottom thread of the filler opening with the
motorcycle held vertical on level ground.
•
•
•
A. Oil Filler Cap
B. Oil Level Sight Gauge
C. H (High) Level Line
D. L (Low) Level Line
If the oil level is too high, remove the excess
oil 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 the
correct level. Use the same type of oil that is
already in the engine.
•
When replacing the cap, be sure the O-ring is
in place, and tighten the cap.
•
A. Bottom Thread
B. Filler Cap
Recommended Engine Oil
If the oil level is too low, add the specified oil.
If the oil level is too high, remove the excess
oil, using a syringe or some other suitable
device.
Type:
API SE, SF or SG
API SH or SJ with JASO MA
•
•
Viscosity: SAE 10W-40
Capacity: 2.9 L (3.1 US qt)
WARNING
[when filter is not removed]
3.1 L (3.3 US qt)
[when filter is removed]
Be careful that no oil gets on the tire, rim,
and brake disc. Clean off any oil that
inadvertently gets on them with oilless
solvent.
Although 10W-40 engine oil is the recom-
mended oil for most conditions, the oil viscosity
may need to be changed to accommodate
atmospheric conditions in your riding area.
CAUTION
Be careful not to allow any dirt or foreign
materials to enter the gear case.
NOTE
żUse the same type of oil that is already in the
final gear case.
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PREPARATION 37
When replacing the filler cap, be sure the O
-ring is in place, and install the cap.
•
Final Gear Case Oil
Type:
API “GL-5”
Hypoid gear oil
Viscosity: 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. Throttle Grip
B. 2 ~ 3 mm (0.08 ~ 0.12 in.)
Run the engine at idle speed, and turn the
•
handlebar all the way to the right and left to
ensure that the idle speed does not change.
If the idle speed increases, check the throttle
grip free play.
WARNING
Operation with an improperly adjusted,
incorrectly routed, or damaged cable
could result in an unsafe riding condi-
tion.
A. Oil Drain Plug
Reinstall the saddlebags. See “Left Saddle-
bag” section in the Assembly chapter.
•
Throttle Grip Free Play Adjustment
Loosen both locknuts of the throttle cables
•
and turn both adjusters in completely to give
the throttle grip plenty of play.
Throttle Grip and Cable
Turn out the decelerator cable adjuster until
there is no play when the throttle grip is com-
pletely closed. Tighten the locknut.
•
Throttle Grip Free Play Inspection
Inspect the throttle grip free play. If the free
play is incorrect, adjust the throttle cables.
•
Throttle Grip Free Play:
2 ~ 3 mm (0.08 ~ 0.12 in.)
Check that the throttle grip moves smoothly
•
from full open to close, and the throttle closes
quickly and completely in all steering posi-
tions by the return spring. If the throttle grip
does 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. Accelerator Cable
B. Decelerator Cable
C. Locknuts
D. Adjusters
Turn out the accelerator cable adjuster un-
til the specified amount of play is obtained.
Tighten the locknut.
•
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38 PREPARATION
Headlight Aim
The headlight beam is adjustable both hori-
zontally and vertically. Headlight aim must be
correctly adjusted for safe riding as well as on-
coming drivers. In most areas it is illegal to ride
with an improperly adjusted headlight.
Horizontal Adjustment
Turn the horizontal adjusting screw on the
headlight rim in or out until the beam points
straight ahead.
•
A. Idle Adjusting Screw
Open and close the throttle grip a few times
to make sure that the idle speed does not
change.
•
With the engine idling, turn the handlebar to
each side. If handlebar movement changes
the idle speed, check the throttle cable routing
and free play.
•
WARNING
Operation with improperly routed, or
damaged throttle cables could result in
an unsafe riding condition.
A. Horizontal Adjusting Screw
B. Vertical Adjusting Screw
Check for any exhaust leaks and correct if
necessary.
•
Vertical Adjustment
Turn the vertical adjusting screw on the head-
•
light rim in or out to adjust the headlight verti-
cally.
Rear Brake Light Switch
Rear Brake Light Switch Adjustment
NOTE
Turn on the ignition switch. The brake light
•
żOn high beam, the brightest point should be
slightly below horizontal with the motorcycle
on its wheels and the rider seated. Adjust
the headlight to the proper angle according to
local regulation.
should illuminate when the brake pedal is de-
pressed about 10 mm (0.4 in.)
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. Brake Pedal
B. 10 mm (0.4 in.)
If it does not, turn the adjusting nut at the rear
brake light switch as required.
•
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PREPARATION 39
A. Rear Brake Light Switch
B. Adjusting Nut
C. Lights sooner.
D. Lights later.
CAUTION
To avoid damaging the electrical con-
nections inside the switch, be sure that
the switch body does not turn during ad-
justment.
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40 PREPARATION
Fastener Check
The torque values listed are for assembly and
•
preparation items only, see the appropriate
Service Manual for a more comprehensive
list. Check tightness of all fasteners that are
in the table before retail delivery. Also check
to see that each cotter pin or circlip is in place.
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PREPARATION 41
Torque
kgf·m
No.
Fastener
Remarks
ft·lb
N·m
Steering
1
2
Handlebar clamp bolts
Steering stem head nut
34
88
3.5
9.0
25
65
Brake
3
4
5
6
7
8
Front master cylinder clamp bolts
Front caliper mounting bolts (Left and Right)
Front brake bleed valves (Left and Right)
Rear master cylinder mounting bolts
Rear caliper mounting bolts
8.8
34
0.90
3.5
78 in·lb
25
S
7.8
25
0.80
2.5
69 in·lb
18
34
3.5
25
Rear brake bleed valves
7.8
0.80
69 in·lb
Wheel
9
Front axle shaft
108
29
11.0
3.0
80
21
10 Front axle clamp bolts (Right)
AL
Suspension
Rear shock absorber mounting nuts (Left and
Right)(Uper and Lower)
11
34
3.5
25
Others
12 Front footboard bracket bolts (Left and Right)
13 Rear footboard bracket bolts (Left and Right)
14 Clutch master cylinder clamp bolts
Engine
34
25
11
3.5
2.5
1.1
25
18
97 in·lb
Engine Oil Drain Plugs:
15 Engine oil drain plug
20
2.0
15
16 Final gear case drain plug
Cotter Pin or Circlip
8.8
0.90
78 in·lb
17 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.
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42 PREPARATION
Control
Cables:
Throttle control cables must
work without binding in any
steering position.
Action is free from
lock-to-lock.
Check operation front and
rear.
Electric starter works
properly and engine starts
promptly. Good throttle
response and return.
Standard Torque Table
This table relating tightening torque to thread
diameter, lists the basic torque for bolts and
nuts. Use this table for only the bolts and nuts
which do not require a specific torque value.
All of the values are for use with dry solvent
-cleaned threads.
Steering:
Suspension:
Engine:
General Fasteners:
Threads
dia. mm
Torque
kgf·m
N·m
ft·lb
30 ~ 43
in·lb
Transmission Smooth operation.
5
6
3.4~4.9 0.35~0.50
5.9~7.8 0.60~0.80
and Clutch:
Brakes:
Adequate, smooth stopping
power, No drag.
Speedometer: Check operation
Electrical System:
Headlight - check high and low beams.
Taillight - check operation.
Brake Light - check operation
Turn Signal Lights - check operation.
Horn - check operation
Instrument 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.
52 ~ 69
in·lb
8
14~19
25~34
44~61
73~98
1.4~1.9 10.0~13.5
2.6~3.5 19.0~25
10
12
14
16
18
20
4.5~6.2
33~45
54~72
7.4~10.0
115~155 11.5~16.0 83~115
165~225 17.0~23.0 125~165
225~325
23~33
165~240
Test Ride the Motorcycle
Complete the test ride checklist.
•
WARNING
New tires are slippery and may cause
loss of control and injury. A break-in pe-
riod of 160 km (100 miles) is necessary
to establish normal tire traction.
During break-in, avoid sudden and maxi-
mum braking and acceleration, and hard
cornering.
A & P Check List
Complete the A & P Check List.
•
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MODEL APPLICATION
Year
Model
Name
VULCAN 1600 NOMAD
VN1600 CLASSIC TOURER
2005
VN1600–D1
Part No. 99931-1445-01
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