INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. Refer to the Service Manual and follow the instructions given to remove the Maxi® Fuse.

• Kawasaki Vulcan 88 Specs
• 1994 Kawasaki Vulcan 1500 88 Service Manual Pdf
• 2000 Vulcan 1500 Classic Specs

Refer to the instructions included with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit, and proceed with that installation until the installation of the items in this kit is called for. Remove the outer fairing and windshield. Refer to OUTER FAIRING/ WINDSHIELD REMOVAL in the Service Manual. On the fairing cap, remove the inner left side hole plug. See Figure 1 and the FAIRING CAP SWITCHES (FLHTC/U) section in the Service Manual. Install the fairing speaker switch (4) in the opening as follows: If a cruise control switch IS present: Follow the instructions in the Service Manual to install the speaker switch.

This Clymer motorcycle manual covers the Kawasaki Vulcan 1500 Series for these. 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995 KAWASAKI VN-15. Vulcan 88 A1-A9 1987-1995 (U.S. And Canada) Vulcan 88. This specific manual is for the Kawasaki Vulcan 1500 spanning 1987-1999. You can see the. Complete service repair workshop manual for the: Kawasaki Vulcan VN1500 Classic Tourer Nomad VN 1500. This is the same manual motorcycle dealerships use to repair your bike.

If a cruise control switch IS NOT present: a. Obtain the speaker switch adapter wire (5) from the kit, and the butt splice connector included with the speaker switch. Refer to SEALED BUTT SPLICE CONNECTORS in the Service Manual. Splice the adapter wire to the black/ green speaker switch lead. Insert the terminated end of the adapter wire into cavity 12 of the fairing cap switch connector 105B 5. Remove the original equipment left-hand control switch assembly per the HANDLEBAR SWITCHES, REMOVAL, LEFT HANDLEBAR CONTROLS instructions in the Service Manual. Install the new left-hand control switch assembly (3) from the kit.

When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. ALL models: Install the console pod assembly (1), and route the harness forward into the fairing per the instructions packaged with the Advanced Audio Hands Free Phone Interface, CB Radio or Intercom Kit. Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury.

(00371a). Be sure the wires do not pull tight when handlebars are turned fully to left or right fork stops.

Unless already installed, install the overlay harness per the instructions packaged with the Hands Free Phone Interface, CB Radio or Intercom Kit. Refer to the Service Manual and follow the instructions given to re-install the Maxi Fuse. 1) Place motorcycle on its side stand on a firm level surface.

2) Remove saddlebags if applicable 3) Attach bracket C (left side) and bracket D (right side) to rearmost fender attachment bolt. A) If bike has no saddlebags use 3/8 spacer between bracket and motorcycle. Use new bolt provided. B) If bike has stock saddlebags use enclosed threaded rod assembly. 1) Thread rod into rear bag/fender mount 2) Place 3/8 spacer and bracket onto rod 3) Tighten down with locknut ensure locknut and rod are tight 4) Replace bags on rod and tighten NO BAGS STOCK BAGS 4) Remove rear riders pegs and attach front of bracket A(left side) and bracket B (right side) to rear foot peg mounting point. Mount foot peg to outside of bracket.

Use new bolts provided. 6) Attach brackets C/D to top of rear hitch plate. 7) Attach rear of brackets A and B to TOP of hitch arms 8) Ensure hitch is square on motorcycle and tighten all bolts Incoming search terms:.

Attach mounting bracket 440-P to frame using two stock fl ange head bolts used on stock upper bracket (Figures 1 and 2). Remove head pipes and heat shields from protective packaging. Place each heat shield on a non-abrasive surface such as a blanket or carpet. Using a felt tip pen, mark outside edge of each heat shield to show location of mounting clips that hose clamps will loop through (Figure 3). Lay front header, and rear header into their head heat shields and muffl er body heat shields. Install #20 hose clamps (supplied) on heat shields and #36 (supplied) on muffl er body heat shields by feeding tail end of clamps into heat shield clips (fi gure 3).

Take note of clamp screw head direction (Figure 4). Screw heads must be accessible when system is installed on motorcycle for adjustment purposes. NOTE: Do not tighten at this time. Using stock fl ange nuts, carefully install head pipes into exhaust ports. Assistance may be required.

NOTE: Do not tighten at this time. Slide nut plates inside bracket that is welded to backside of muffl er bodies (Figure 5). While holding nut plates in place, attach muffl er bodies to mounting bracket 440-P using two 5/16″x 5/8″ fl ange head bolts (supplied). Leave them loose at this time. Align muffl er bodies so they are level and parallel when viewing from the right side of the bike. Tighten cylinder port exhaust fl ange nuts on front and rear cylinders. Tighten the fl ange bolts on both muffl ers.

Tighten all heat shield clamps. Check for adequate clearance of all exhaust system components and motorcycle accessories prone to heat damage. NOTE: For models with fl oorboards, two Spacer washers are supplied to space out the fl oorboard bracket enough to allow the fl oorboard to fold up without hitting the heat shield.

Be sure to tighten all hardware before starting your motorcycle. After installation and before starting motorcycle, completely clean pipes and muffl ers with cleaning solvent and a clean, soft cloth that will not leave a residue. NOTE: Any residue, oil, or fi ngerprints will stain the chrome when the metal heats up.

1) Place motorcycle on its side stand on a firm level surface. 2) Remove saddlebags if any. 3) Remove rear riders pegs. 4) Attach front of bracket A (left side) and bracket B (right side) between rear footpeg motorcycle bracket and rear footpeg. Use new bolt provided (Bolt assortment included to accommodate some accessories) 5) Attach bracket E (left side) and bracket F (right side) to two rear fender attachment bolts.

Use new bolts provided. (Bolt assortment included to accommodate some accessories) 6) Attach bracket C (left side) and bracket D (right side) to brackets E and F and to second holes on rear of hitch. 7) Attach rear of brackets A and B to BOTTOM of hitch arms 8) Tighten all bolts. Receiver hitch diagram Leveling stand screw jack installation After hitch is installed, install leveling stand screw jacks to hold motorcycle in an upright and level position in order to install or remove InstaTrike. 1) Thread right side screw jack into leveling stand bracket on bracket B and adjust leveling jack bolt out until motorcycle will be level against it. 2) Push motorcycle over from left side until right screw jack is touching floor.

Incoming search terms:. The actuator spool is installed in the CIU housing with the actuator cable. The actuator spool is rotated to fully extend the cable. The dual spool and carburettor cable are installed. The carburettor cable is attached to the lower groove in the dual spool. The other end of the carburettor cable is attached to the carburettors.

Note the position of the roll pin. It is nearly contacting the end of the groove in the actuator spool. The free play in the carburettor cable must be adjusted so that the cable outer can be pulled out 2 3mm before the carburettors start to open. This ensures that the cruise control cannot prevent the carburettors returning to idle. If more free play is allowed the response of the cruise control is compromised. This adjustment of free play is usually performed after final assembly of the CIU is completed and the CIU is in its final location. This is because flexing the cable affects the free play.

It is shown at this stage in these diagrams to improve clarity. After this adjustment is performed, the carburettor cable adjustment MUST NOT BE MOVED.

All future adjustments of free play in the throttle must be performed on the throttle cable from the throttle grip. If incorrect free play in the carburettor cable is suspected due to inconsistent cruise operation or because of inconsistent idle speed, the adjusters on the throttle cable from the hand grip must be backed all the way off to give as much free play as possible. If this does not result in AT LEAST 5mm of free play in the throttle cable, the throttle cable must be removed from the hand grip or CIU before adjustment of the carburettor cable is attempted. This is crucial because the amount of free play in the throttle cable also affects the apparent free play in the carburettor cable. Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding.

(00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4.

“E”-clip (keep) 5. Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8. Wheel assembly (replace) 9. Valve cap (keep) 10.

Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1.

Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse. Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual.

Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Re-assemble all saved components to the new chrome rear wheel assembly. See REAR WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier.

Hitachi tv service manual 420325p. Hitachi 50v500 60v500a tv service manual download ebook hitachi 50v500. Manualhitachi tv repair manuals file type pdf hitachi tv service manual 4203. Full download hitachi ct4271 projection color tv repair manual het chassis het. Also for 22e30 49e30 49e301 a0 hitachi tv service manual 4203. Jul 17, 2015 - guides and service manuals. Free hitachi projection television user. Hitachi tv service manual 4203 pdf download - hitachi tv and video user.

Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual.

Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Mark the left and right brake discs so they can be re-installed to the same location. Re-assemble all saved components to the new chrome front wheel assembly.

See FRONT WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7.

Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury.

Kawasaki Vulcan 88 Specs

(00279a) After servicing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99.

Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84 Incoming search terms:. REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift. NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system.

1994 Kawasaki Vulcan 1500 88 Service Manual Pdf

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. Disconnect battery cables, negative (-) battery cable first. Remove seat according to the instructions in the service manual.

Refer to service manual to remove left saddlebag and side cover. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity.

Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1.

Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual. Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual.

Remove engine from chassis following the instructions in the service manual. Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual. Remove existing clutch diaphragm spring.

Refer to CLUTCH REMOVAL in service manual. The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1. O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1.

Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in.

(112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). Remove cylinder studs from the engine crankcase. Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. Inspect and clean engine case mating surfaces. See Figure 6.

Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm).

See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase Incoming search terms:. Cover the throttle bodies to prevent anything from dropping into the engine.

Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4.

Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6. Lower the fuel tank. (Refer to Service Manual, Page 5-3) 7.

2000 Vulcan 1500 Classic Specs

Remove the upper seat rail plate. Disconnect and remove the ECM.

(Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft)! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring. Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque. Remove and replace the ISC valve.

(Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.! Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3.

Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate. Incoming search terms:.