The 2003-2008 Kawasaki Vulcan VN1600 Classic, Mean Streak, Nomad Repair Manual by Clymer covers the following models:

• Kawasaki Vulcan VN1600 Classic A, E, 2003-2008
• Kawasaki Vulcan VN1600 Mean Streak B, F, 2004-2008
• Kawasaki Vulcan VN1600 Nomad D, G, 2005-2008

Like all Clymer repair and service manuals available from The Motor Bookstore, this do-it-yourself guide provides a detailed look at 2003-2008 Kawasaki VN1600 Series models, with hundreds of close-up photos and illustrations that accompany easy-to-understand text, so you can maintain or repair your Vulcan properly.
Book Excerpt: 2003-2008 Kawasaki Vulcan 1600 Classic, Mean Streak, Nomad Repair Manual ENGINE LOWER END

SHIFT LINKAGE REMOVAL, ADJUSTMENT, INSTALLATION The shift linkage consists of the front and rear shift levers and linkage rod (Figure 24).

1. Remove the shift pedals as described in this section.
2. Remove the alternator outer cover (Chapter Nine).
3. Remove the engine as described in this chapter.
4. Pull the front shift lever (A, Figure 24) out of the alternator inner cover.
5. Remove the pinch bolt (B, Figure 24) and remove the front (A) and rear (C) shift levers.
NOTE: The rear locknut uses left-hand threads.
6. To service the shift linkage, perform the following:
1. Loosen the front and rear locknuts and turn the shift linkage rod to remove it.
2. Replace the damaged part.
3. . Perform Step 7 to adjust the shift linkage.
7. To adjust the shift linkage, perform for following:
1. Loosen the locknuts and turn the shift linkage until the distance between the outside of each locknut (D, Figure 24) is 111-113 mm (4.36-4.44 in.).
2. Tighten the locknuts to 11 Nm (97 in.-lb.).
8. Make sure the E-clip is installed in the front shift lever's groove. Replace the E-clip if weak or damaged.
9. Install the rear shift lever by aligning its punch mark with the punch mark on the shift shaft (Figure 25). Tighten the pinch bolt (B, Figure 24) to 12 Nm (106 in.-lb.).
10. Install the front shift lever into the alternator inner cover. (A, Figure 24).
11. Reverse Steps 1-3.

FUEL SYSTEM

FUEL INJECTION MAIN RELAY The fuel injection main relay controls power to the ECU, fuel pump, fuel injectors and idle speed control valves. REMOVAL AND INSTALLATION

1. Disconnect the negative battery cable (Chapter Nine).
2. Remove the right side cover (Chapter Fifteen).
3. Remove the coolant reserve tank (Chapter Ten).
4. Remove the relay (Figure 25) from its mounting position, then disconnect the connector and remove the relay.
5. Clean the connector.
6. Installation is the reverse of removal.

Subject: 2003, 2004, 2005, 2006, 2007, 2008 Kawasaki Vulcan VN1600 Classic, Mean Streak, Nomad service, maintenance, and repair procedures. ISBN-10: 1599695146 | ISBN-13: 9781599695143 | Clymer M245