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2003-2008 Kawasaki Vulcan 1600 Classic Maintenance Schedule and Service Intervals

2003-2008 Kawasaki Vulcan 1600 Classic Stock Image

This is the maintenance schedule with associated service intervals for the 2003-2008 Kawasaki Vulcan 1600 Classic.

The Kawasaki Vulcan is a cruiser style motorcycle. The Vulcan name has been used for custom or cruiser motorcycles since 1984, model designation VN, using mostly V-twin engines ranging from 125 to 2,053 cc (7.6 to 125.3 cu in).

This maintenance schedule applies to the following models:

  • 2003 Kawasaki Vulcan 1600 Classic
  • 2004 Kawasaki Vulcan 1600 Classic
  • 2005 Kawasaki Vulcan 1600 Classic
  • 2006 Kawasaki Vulcan 1600 Classic
  • 2007 Kawasaki Vulcan 1600 Classic
  • 2008 Kawasaki Vulcan 1600 Classic

The Kawasaki Vulcan 1600 power is provided by a 4-Stroke, 1552cc, Liquid / Air cooled, SOHC, V Twin engine with Electric starter. The engine is paired with a 5-Speed transmission and total fuel capacity is 5.3 gallons.

Maintenance Schedule for 2003-2008 Kawasaki Vulcan 1600 Classic

Below is the maintenance schedule for the 2003-2008 Kawasaki Vulcan 1600 Classic.

The following is the list of maintenance operations and to be done on this motorcycle with a time or distance interval — whichever comes earlier.

Periodic Maintenance Chart

OperationEvery1000 km (600 mi)6000 km (4000 mi)12000 km (7500 mi)18000 km (12000 mi)24000 km (15000 mi)30000 km (20000 mi)36000 km (24000 mi)
Idle speed–check † (e)
Throttle control system–check † (e)
Spark plug–clean and gap † (e)
Air suction valve – check † (e)
Air cleaner element–clean †# (e)
Evaporative emission control system (Cal) – check † (e)
KBrake/clutch hoses, connections – check †
Brake light switch – check †
Brake pad wear – check †#
Brake/clutch fluid level – check †month
KBrake/clutch fluid – change2 years
KFuel hose, connectuions – check †
KSteering –check †
Final gear case oil level – check †
Final gear case oil – change
KPropeller shaft joint – lubricate
Nut, bolt, fastener tightness – check †
Tire wear – check †
Engine oil – change #year
Oil filter – replace
General lubrication – perform
Front fork oil leak – check †
Rear shock absorber oil leak – check †
KSwingarm pivot – lubricate
KCoolant – change2 years
Radiator hoses, connectinos – check †
KSteering stem bearing – lubricate2 years
KBrake/clutch master cylinder cup and dust seal – replace4 years
KCaliper piston seal and dust seal – replace4 years
KClutch slave cylinder piston seal – repalce4 years

Notes:

K: Should be serviced by an authorized Kawasaki dealer
*: For higher odometer readings, repeat at the frequency interval established here
†: Replace. add. adjust, or torque if necessary.
#: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
e: Emission related item
Cal: California model only

Tyre size and tyre pressure for the 2003-2008 Kawasaki Vulcan 1600 Classic

The 2003-2008 Kawasaki Vulcan 1600 Classic has the following tyres and tyre sizes standard (tubeless type):

Front:

  • 130/90-16 M/C 67H
  • BRIDGESTONE “EXEDRA G721”
  • DUNLOP “D404 FZ”

Rear:

  • 170/70 B16 M/C 75H
  • BRIDGESTONE “EXEDRA G722”
  • DUNLOP “D404”

The manual for the 2003-2008 Kawasaki Vulcan 1600 Classic recommends the following tyre pressures (when cold):

  • Front (up to 186 kg load [410 lb]): 200 kPa/28 psi
  • Rear (up to 186 kg load [410 lb]): 250 kPa/36 psi

General information about the 2003-2008 Kawasaki Vulcan 1600 Classic

A 95-cubic inch V-twin engine generating plenty of low-end torque and supplying the Vulcan 1600 Classic with more than enough power for just about anything its rider chooses to do. Extra power is nice for playtime, but when a plan calls for extended seat-time, the single-pin crankshaft, and a gear-driven counter balancer work together to provide a comforting rhythm without those harsh vibrations.

Complementing the engine’s power is a large, 41mm telescopic fork and the stout frame, which provide maximum rigidity for superb steering feel, easy side-to-side transitions, and excellent ride quality. Dual rear shocks with four-way adjustable damping deliver exceptional comfort for long days in the saddle. Cast seven-spoke wheels allow the use of large tubeless tires and wide fenders to give the 1600 Classic its tough look.

A wide, pullback handlebar, stepped seat, dual slash-cut mufflers, and a multi-reflector headlight are several of the design details that make the 1600 Classic a one-of-a-kind American classic. Features of the tank-mounted, integrated instrument cluster include an LCD screen, ignition switch, fuel-injection warning lamp, fuel gauge, odometer, trip meter, and clock.

Manual for the 2003-2008 Kawasaki Vulcan 1600 Classic

2003-2008 Kawasaki Vulcan 1600 Classic Maintenance Schedule Screenshot From Manual
User manual screenshot for the 2003-2008 Kawasaki Vulcan 1600 Classic

The above maintenance schedule comes directly from the user’s manual for the 2003-2008 Kawasaki Vulcan 1600 Classic, which is available here.

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