Kawasaki VN1500 Mensreak Service.pdf

VULCAN 1500 MEAN STREAK

VN1500 MEAN STREAK

Service Manual

form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of

Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been

taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make

such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product

improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication.

Illustrations and photographs in this publication are intended for reference use only and may not depict actual model

component parts.

First Edition (1) : Jul. 15, 2001 (M)

Motorcycle

LIST OF ABBREVIATIONS

ampere(s)

pound(s)

ABDC

after bottom dead center

meter(s)

alternating current

min

minute(s)

ATDC

after top dead center

newton(s)

BBDC

before bottom dead center

pascal(s)

BDC

bottom dead center

horsepower

BTDC

before top dead center

psi

pound(s) per square inch

degree(s) Celsius

revolution

direct current

r/min, rpm

revolution(s) per minute

farad(s)

TDC

top dead center

degree(s) Fahrenheit

TIR

total indicator reading

foot, feet

volt(s)

gram(s)

watt(s)

hour(s)

ohm(s)

liter(s)

Read OWNER’S MANUAL before operating.

EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission

(2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and

California Air Resources Board. Additionally, Kawasaki has incorporated an evaporative emission control system (3) in

compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only.

1. Crankcase Emission Control System

This system eliminates the release of cranckcase vapors into the atmosphere. Instead, the vapors

are routed through an oil separator to the inlet side of the engine. While the engine is operating, the

vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied

by the fuel injection system.

2. Exhaust Emission Control System

This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this

motorcycle. The fuel, ignition, and exhaust systems of this motorcycle have been carefully designed

and constructed to ensure an efcient engine with low exhaust pollutant levels.

The exhaust system of this model motorcycle manufactured primarily for sale in California includes a

catalytic converter system.

3. Evaporative Emission Control System

Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. Instead,

fuel vapors are routed into the running engine to be burned, or stored in a canister when the engine

is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.

The Clean Air Act, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to as

the Act’s "tampering provisions."

"Sec. 203(a) The following acts and the causing thereof are prohibited...

(3)(A) for any person to remove or render inoperative any device or element of design installed on or

in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to

its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer knowingly to

remove or render inoperative any such device or element of design after such sale and delivery

to the ultimate purchaser.

(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading motor

vehicles or motor vehicle engines, or who operates a eet of motor vehicles knowingly to remove

or render inoperative any device or element of design installed on or in a motor vehicle or motor

vehicle engine in compliance with regulations under this title following its sale and delivery to the

ultimate purchaser..."

NOTE

The phrase "remove or render inoperative any device or element of design" has been generally

interpreted as follows:

1. Tampering does not include the temporary removal or rendering inoperative of devices or

elements of design in order to perform maintenance.

2. Tampering could include:

a. Maladjustment of vehicle components such that the emission standards are exceeded.

b. Use of replacement parts or accessories which adversely affect the performance or

durability of the motorcycle.

c. Addition of components or accessories that result in the vehicle exceeding the standards.

d. Permanently removing, disconnecting, or rendering inoperative any component or element

of design of the emission control systems.

WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF

WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION.

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person

other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any

new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2)

the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

•

Replacement of the original exhaust system or mufer with a component not in compliance with Federal

regulations.

•

Removal of the mufer(s) or any internal portion of the mufer(s).

•

Removal of the air box or air box cover.

•

Modications to the mufer(s) or air inlet system by cutting, drilling, or other means if such modications

result in increased noise levels.

Foreword

This manual is designed primarily for use by trained

mechanics in a properly equipped shop. However, it

contains enough detail and basic information to make

it useful to the owner who desires to perform his own

basic maintenance and repair work. A basic knowledge

of mechanics, the proper use of tools, and workshop

procedures must be understood in order to carry out

maintenance and repair satisfactorily. Whenever the

owner has insufcient experience or doubts his ability to

do the work, all adjustments, maintenance, and repair

should be carried out only by qualied mechanics.

In order to perform the work efciently and to avoid

costly mistakes, read the text, thoroughly familiarize

yourself with the procedures before starting work, and

then do the work carefully in a clean area. Whenever

special tools or equipment are specied, do not use

makeshift tools or equipment. Precision measurements

can only be made if the proper instruments are used,

and the use of substitute tools may adversely affect safe

operation.

For the duration of the warranty period, we rec-

ommend that all repairs and scheduled maintenance be

performed in accordance with this service manual. Any

owner maintenance or repair procedure not performed in

accordance with this manual may void the warranty.

To get the longest life out of your vehicle:

• Follow the Periodic Maintenance Chart in the Service

Manual.

• Be alert for problems and non-scheduled maintenance.

Each chapter in turn has its own comprehensive Table of

Contents.

If you want ignition coil information, for example, use

the Quick Reference Guide to locate the Electrical System

chapter. Then, use the Table of Contents on the rst page

of the chapter to nd the Ignition Coil section.

Whenever you see these WARNING and CAUTION

symbols, heed their instructions! Always follow safe

operating and maintenance practices.

This warning symbol identies special instruc-

tions or procedures which, if not correctly fol-

lowed, could result in personal injury, or loss of

life.

CAUTION

This caution symbol identies special instruc-

tions or procedures which, if not strictly ob-

served, could result in damage to or destruction

of equipment.

This manual contains four more symbols (in addition to

WARNING and CAUTION) which will help you distinguish

different types of information.

NOTE

• Use proper tools and genuine Kawasaki Motorcycle

parts. Special tools, gauges, and testers that are

necessary when servicing Kawasaki motorcycles are

introduced by the Special Tool Catalog or Manual.

Genuine parts provided as spare parts are listed in the

Parts Catalog.

• Follow the procedures in this manual carefully. Don’t

take shortcuts.

• Remember to keep complete records of maintenance

and repair with dates and any new parts installed.

This note symbol indicates points of particular in-

terest for more efcient and convenient operation.

• Indicates a procedural step or work to be done.

Indicates a procedural sub-step or how to do the work

of the procedural step it follows. It also precedes the

text of a NOTE.

Indicates a conditional step or what action to take based

on the results of the test or inspection in the procedural

step or sub-step it follows.

In most chapters an exploded view illustration of the

system components follows the Table of Contents. In

these illustrations you will nd the instructions indicating

which parts require specied tightening torque, oil, grease

or a locking agent during assembly.

How to Use This Manual

In preparing this manual, we divided the product into

its major systems. These systems became the manual’s

chapters.

The Quick Reference Guide shows you all of the

product’s system and assists in locating their chapters.

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