Kawasaki Vulcan 1600 Series Motorcycle (2003-2008) Service Repair Manual Description Kawasaki Vulcan 1600 Series Service and Repair Manual (2003-2008) M245This manual covers all models of Kawasaki Vulcan 1600 Series motorcycles including: Classic Mean Streak and Nomad Manual. Includes Color Wiring Diagrams. This service manual provides specific detailed instructions for performing everything from basic maintenance and troubleshooting to a complete overhaul of all models of the Kawasaki Vulcan 1600 Series motorcycle. Do-it-yourselfers will find this service and repair manual more comprehensive than the factory manual making it an indispensable part of your tool box. Every Clymer manual contains hundreds of original photographs and illustrations developed from a complete disassembly and assembly of a motorcycle. This in addition to extensive research allows Clymer to achieve an unmatched level of detail accuracy and clarity. The step-by-step instructions and two-column text with large print are user-friendly. Bold figure numbers make it easy to quickly match instructions with illustrations and photos. Thumb-tabbed chapters numbered table of contents and an extensive index make it possible to locate the desired section quickly. Contents This Kawasaki Vulcan 1600 Manual is 480 pages. QUICK REFERENCE DATA CHAPTER ONE / GENERAL INFORMATION Manual organization / Warnings cautions and notes / Safety / Serial numbers and information labels / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications CHAPTER TWO / TROUBLESHOOTING Starting the engine / Engine does not start / Poor engine performance / Electronic diagnostic system / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Electrical testing / Charging system / Ignition system / Starting system / Final drive / Front suspension and steering / Brake system / Specifications CHAPTER THREE / LUBRICATION MAINTENANCE and TUNE-UP Maintenance schedules / Tune-up / Cylinder identification and firing order / Air filter / Engine compression test / Spark plugs / Ignition timing / Idle speed adjustment / Fuel hose inspection / Fuel pump screen and fuel filter / Throttle cable / Choke cable / Control cable lubrication / Brake and clutch lever lubrication / Clutch / Engine oil and filter / Cooling system / Evaporative emission control systems / Battery / Final drive oil / Drive shaft lubrication / Tires and wheels / Steering bearings / Front suspension check / Rear suspension check / Brakes / Headlight adjustment / Sidestand and ignition cut-off switch test / Engine stop switch check / Front fork oil change / Swing arm bearing lubrication / General lubrication / Fastener inspection / Specifications CHAPTER FOUR / ENGINE TOP END Rocker case cover / Rocker case / Cam chain tensioner / Camshaft / External oil hoses / Cylinder head / Valves and valve components / Cam chain and chain guide / Cylinder / Piston and piston rings / Specifications CHAPTER FIVE / ENGINE LOWER END Servicing engine in frame / Engine removal/installation / Shift pedal and shift linkage / External shift mechanism / Front bevel gearcase / Drive gear / Driven gear / Front bevel gear adjustments / Starter gears / Primary drive gear and water pump / drive mechanism / Balancer gears / Crankcase / Crankcase bearings / Crankshaft / Connecting rods / Balancer shaft / Oil pump and oil pressure relief / valve / Break-in / Specifications CHAPTER SIX / CLUTCH Clutch bleeding / Clutch fluid draining and flushing / Clutch master cylinder / C...