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2004 to 2006 Kawasaki Vulcan 1600 VN1600 Mean Streak Service Repair Manual

2004 2005 2006 Kawasaki Vulcan 1600 VN1600 Mean Streak Service Repair Manual pdf  download

This is the most practical Service Repair Manual for the 2004-2006 Kawasaki Vulcan 1600 VN1600 Mean Streak Service Repair Manual Download ever compiled by mankind. Manual covers all the topics like: Engine Service, General Information, Transmission, Chassis, Lighting , Cooling System Seats System, Clutch, Suspension, Locks, Brakes, Lubrication, Electrical System , Frame Fuel System,Fuel System (DFI)  etc

Model Identification

  • VN1600-B1 (US, and Canada)
  • VN1600-B1 (Europe)

This manual covers 



Basic Torque for General Fasteners

Throttle Grip Free Play

Idle Speed

Water and Coolant Mixture Ratio (when shipping)

Engine Oil

Tread Depth

Air Pressure (when cold)

Final Gear Case Oil:

Pad Lining Thickness

Sample Diagnosis Sheet

Engine Doesn’t Start, Starting Difficulty

Poor Running at Low Speed

Poor Running or No Power at High Speed:

Throttle Sensor Input Voltage

Idle Speed

Throttle Sensor Output Voltage

Throttle Sensor Resistance

Inlet Air Pressure Sensor Input Voltage

Inlet Air Pressure Sensor Output Voltage

Digital Volt Meter Connections

Inlet Air Temperature Sensor Output Voltage

Inlet Air Temperature Sensor Resistance

Water Temperature Sensor Output Voltage

Water Temperature Sensor Resistance

Atmospheric Pressure Sensor Input Voltage

Atmospheric Pressure Sensor Output Voltage

Vehicle-down Sensor Power Source Voltage

Vehicle-down Sensor Output Voltage

Fuel Line Maximum Pressure

Injector Power Source Voltage at DFI Main Relay

Injector Output Voltage at ECU

Injector Wiring Inspection

Injector Resistance

Pump Power Source Voltage

Pump Operating Voltage at Pump Connector

Ignition Coil Input Voltage at ECU

ECU Identification

ECU Power Source Inspection

Power Source Voltage at ISC Valve Connector

ISC Valve Solenoid Resistance (##1, ##2)

Fuel Pressure (idling)

Fuel Pressure (with throttle fully opened)

Thermostat Valve Opening Temperature

Air Switching Valve Resistance

Camshaft/Rocker Case Clearance

Camshaft Journal Diameter

Valve-to-Guide Clearance (Wobble Method)

Valve Seat Surface Outside Diameter (Seat O.D.)

[For Exhaust Valve Seat]

Cylinder Inside Diameter

Spring Plate Gap

Connecting Rod Bend

Big End Bearing Insert Selection

Crankcase Main Bearing Bore Diameter

Shift Fork Ear Thickness

Shift Drum Groove Width

Preload for Pinion Gear Bearing

Final Bevel Gear Backlash:

Front Bevel Gear Backlash (at the gear tooth)

Front Disc Thickness

Kawasaki-recommended chargers:

Terminal Voltage: less than 11.5 V

Ignition Coil Arcing Distance

Ignition Coil Primary Peak Voltage

Crankshaft Sensor Peak Voltage

Interlock Operation Voltage

Testing Turn Signal Control Relay Inspection

FI Indicator LED Light Connections:

Fuel Level Indicator Light Connections:

Fan Switch Resistance

Relay Circuit Inspection (with the battery disconnected)

and more


Read OWNER’S MANUAL before operating.




General Information

Periodic Maintenance

Fuel System (DFI)

Cooling System

Engine Top End


Engine Lubrication System

Engine Removal/Installation



Final Drive

B rakes




Electrical System


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