Kawasaki Vulcan 1500 Classic, Drifter, Nomad Repair Manual 1996-2008

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Item # M471-3  ISBN: 9781599691701

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This repair & service manual covers Kawasaki Vulcan 1500 Series including...

• Vulcan Classic D1-D2, 1996-1997
• Vulcan Classic E1-E7, 1998-2004
• Vulcan Classic N1-N8, 2000-2008
• Vulcan Classic T6, 2006
• Vulcan Drifter J1-J2, 1999-2000
• Vulcan Drifter R1-R5, 2001-2005
• Vulcan Nomad G1, G1A, G2A, G3, 1998-2001
• Vulcan Nomad L1-L5, 2000-2004

See Clymer M357-2 for 1987-1999 Vulcan 1550A, B and C models.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Warnings,cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Tools | Measuring tools | Electrical system fundamentals | Service methods | Storage | Specifications

CHAPTER TWO: TROUBLESHOOTING
Starting the engine | Engine does not start | Engine performance | Electronic diagnostic system | Engine noises | Engine lubrication | Clutch | Gearshift linkage | Transmission | Fuel system | Electrical testing | Lighting system | Charging system | Ignition system | Starting system | Front suspension and steering | Brake system | 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 inspection | 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
Right crankcase cover | Left crankcase outer cover | Front bevel gearcase | Bevel gears | 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 | Clutch inner hub | Clutch master cylinder | Clutch hose assembly | Slave cylinder | Clutch hydraulic system | Specifications

CHAPTER SEVEN: TRANSMISSION and INTERNAL SHIFT MECHANISM
Transmission | Transmission inspection | Internal gearshift mechanism | Specifications

CHAPTER EIGHT: CARBURETOR, FUEL, EMISSION CONTROL and EXHAUST SYSTEMS
Carburetor | Throttle position sensor (TPS) | Throttle cable replacement | Choke cable replacement | Air filter housing | Fuel tank | Fuel valve | Fuel level sensor | Fuel pump | Fuel filter | Crankcase breather inspection | Clean air system | Evaporative emission control system | Exhaust 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 | Evaporative emission control system | Throttle cable replacement | Choke cable replacement | Exhaust system | Specifications

CHAPTER TEN: ELECTRICAL SYSTEM
Electrical component replacement | Electrical connectors | Negative battery cable | Battery | Charging system | Regulator-rectifier | Alternator rotor and stator | Ignition system | Starting system | Starter | Starter relay | Starter circuit relay | Lighting system | Switches | Oil pressure warning system | Relays | Meter unit(L2-L4, N, R and T models), Turn signal canceling system | Speed sensor (L2-L4, N, R and T models) | Fuel level system | Cooling system | Fuel pump (D, E and G models) | Fuses and junction box | Wiring diagrams | Specifications

CHAPTER ELEVEN: COOLING SYSTEM
Cooling system safety | 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 | Tires | Wheel balance | 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

COLOR WIRING DIAGRAMS

Kawasaki Vulcan 1500 Classic, Drifter, Nomad Repair Manual 1996-2008