1987-1999 Kawasaki VN1500, Vulcan 1500 service manual

Product Information

Table of Contents

General Information

• 1.1 Model Identification
• 1.2 Technical Specifications
• 1.3 Service Data
• 1.4 Maintenance Schedule

Fuel System

• 2.1 Fuel Tank
• 2.2 Fuel Pump
• 2.3 Fuel Lines
• 2.4 Carburetor/EFI

Cooling System

• 3.1 Radiator
• 3.2 Coolant
• 3.3 Water Pump
• 3.4 Cooling Fan

Engine Top End

• 4.1 Cylinder Head
• 4.2 Valves
• 4.3 Camshaft
• 4.4 Timing Chain/Belt

Clutch

• 5.1 Clutch Lever
• 5.2 Clutch Cable/Hydraulics
• 5.3 Clutch Plates
• 5.4 Clutch Basket

Engine Lubrication System

• 6.1 Oil Pump
• 6.2 Oil Filter
• 6.3 Oil Cooler
• 6.4 Oil Pan

Engine Removal/Installation

• 7.1 Engine Removal Procedure
• 7.2 Engine Installation Procedure

Crankshaft/Transmission

• 8.1 Crankshaft
• 8.2 Bearings
• 8.3 Transmission Gears
• 8.4 Shifting Mechanism

Wheels/Tires

• 9.1 Front Wheel
• 9.2 Rear Wheel
• 9.3 Tire Removal/Installation
• 9.4 Wheel Balancing

Final Drive

• 10.1 Drive Shaft
• 10.2 Drive Chain/Belt
• 10.3 Sprockets
• 10.4 Differential

Brakes

• 11.1 Front Brakes
• 11.2 Rear Brakes
• 11.3 Brake Lines
• 11.4 Brake Fluid

Suspension

• 12.1 Front Forks
• 12.2 Rear Shock Absorbers
• 12.3 Suspension Adjustment

Steering

• 13.1 Steering Head
• 13.2 Handlebar
• 13.3 Steering Damper

Frame

• 14.1 Frame Inspection
• 14.2 Frame Repair
• 14.3 Subframe

Electrical System

• 15.1 Wiring Diagram
• 15.2 Battery
• 15.3 Starter Motor
• 15.4 Charging System
• 15.5 Lighting System
• 15.6 Instrument Panel

Appendix

• 16.1 Troubleshooting
• 16.2 Torque Specifications
• 16.3 Special Tools
• 16.4 Conversion Tables

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