Kawasaki Vulcan 1500 Classic E1-E7 (1998 - 2004) Clymer

This Kawasaki Vulcan 1500 Motorcycle Manual is 448 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Washing the bike / Special tips / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Gasket remover / Threadlocking compound / Expendable supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Special tools / Fabricating tools / Mechanicâ??s tips / Ball bearing replacement / Seals / Riding safety / Storage / Specifications

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Starting the engine / Emergency troubleshooting / Engine starting troubleshooting / Engine performance / Engine noises / Engine lubrication / Clutch / Gearshift linkage / Transmission / Electrical troubleshooting / Test equipment / Basic test procedures / Electrical problems / Charging system troubleshooting / Ignition system troubleshooting / Starter system troubleshooting / Carburetor troubleshooting / Excessive vibration / Front suspension and steering / Brake problems / Specifications

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Tune-up /Air filter / Engine oil and filter / Idle speed adjustment / Spark plugs / Battery / Compression test / Ignition timing inspection / Brake system / Clutch system / Cooling system / Fuel hose inspection / Emission control systems / Throttle cable operation and adjustment / Control cable lubrication / Gearshift pedals / Tires and wheels / Lights and horn inspection / Sidestand switch and ignition cut-off system / Steering head bearing inspection / Front suspension inspection / Rear suspension inspection / Swing arm bearing lubrication / Final drive unit / Speedometer cable lubrication / Fasteners / Specifications

CHAPTER FOUR / ENGINE TOP END
Shop cleanliness / Engine / Rocker case cover / Rocker case / Camshaft and cam chain tensioner / External oil hoses / Cylinder head / Valves / Cylinder / Piston and piston rings / Specifications

CHAPTER FIVE / ENGINE LOWER END END
Right crankcase cover / Left crankcase outer cover / Front bevel gearcase / Bevel gears / Driven gear / Primary drive gear and water pump drive mechanism / Starter gears / Oil pump / Balancer weights / Balancer drive gear / Balancer shaft / Crankcase / Crankshaft and connecting rods / Break-in / Specifications

CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM
Gearshift pedals / Gearshift pedal shaft / External gearshift mechanism / Clutch inner hub / Master cylinder / Clutch hose assembly / Slave cylinder / Specifications

CHAPTER SEVEN / TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission / Transmission inspection / Internal gearshift mechanism / Specifications

CHAPTER EIGHT / CARBURETOR, FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS
Throttle position sensor TPS / Fuel tank / Fuel valve / Fuel level sensor / Fuel pump / Fuel filter / Crankcase breather inspection / Clean air system / Evaporative emission control system / Specifications

CHAPTER NINE / FUEL INJECTION, EMISSION CONTROL AND EXHAUST SYSTEM
Digital fuel injection DFI / Fuel delivery system tests / Fuel pump / Fuel injection main relay / Fuel pressure regulator / Induction system / Idle speed control valves / Throttle body / Intake manifold / Fuel injectors / Throttle position sensor TPS / Atmospheric pressure AP sensor / Vacuum sensor / Engine coolant temperature ECT sensor / Intake air temperature IAT sensor / Vehicle down sensor / Ignition pickup coils / Fuel tank / Fuel return check valve / Fuel level system / Clean air system / Exhaust system / Specifications

CHAPTER TEN / ELECTRICAL SYSTEM
Charging system / Regulator-rectifier / Alternator rotor and stator / Ignition system / Starting system / Starter / Lighting / Switches / Oil pressure warning system / Relays / Meter unit / Turn signal canceling system / Speed sensor / Fuel level system / Fuel pump / Fuses and junction box / Specifications

CHAPTER ELEVEN / COOLING SYSTEM
Radiator and fan / Cooling fan switch / Coolant temperature sending unit / Thermostat / Water pump / Specifications

CHAPTER TWELVE / WHEELS AND TIRES
Front wheel / Rear wheel / Rear wheel coupling / Wheel and axle inspection / Front and rear hubs / Laced wheels / Cast wheels / Wheel balance / Tires / Specifications

CHAPTER THIRTEEN / FRONT SUSPENSION AND STEERING
Handlebar / Front fork / Steering head and stem / Steering head bearings / Steering bearing adjustment / Specifications

CHAPTER FOURTEEN / REAR SUSPENSION AND FINAL DRIVE
Shock absorber / Final drive unit / Swing arm and drive shaft / Specifications

CHAPTER FIFTEEN / BRAKES
Brake service / Brake pad replacement / Front brake caliper / Rear brake caliper / Caliper repair / Front master cylinder / Rear master cylinder and brake pedal / Brake bleeding / Brake disc / Specifications

CHAPTER SIXTEEN / BODY AND FRAME
Front seat / Rear seat / Side covers / Front footrests / Rear footpegs / Rear footrests / Sidestand / Front fender / Rear fender / Saddlebags / Windshield and brackets / Wind deflectors / Front frame guard / Steering head covers / Specifications

INDEX

COLOR WIRING DIAGRAMS

Models covered:
1996 1997 KAWASAKI Vulcan Classic D1 D2 1998 1999 2000 2001 2002 2003 2004 KAWASAKI Vulcan Classic E1 E2 E3 E4 E5 E6 E7
2000 2001 2002 2003 2004 2005 2006 2007 2008 KAWASAKI Vulcan Classic N1 N2 N3 N4 N5 N6 N7 N8
2006 KAWASAKI Vulcan Classic T6
1999 2000 KAWASAKI Vulcan Drifter J1 J2
2001 2002 2003 2004 2005 KAWASAKI Vulcan Drifter R1 R2 R3 R4 R5
1998 1999 2000 2001 KAWASAKI Vulcan Nomad G1 G1A G2A G3
2000 2001 2002 2003 2004 KAWASAKI Vulcan Nomad L1-L5
VN1500 VN 1500

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