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Kawasaki Vulcan 1500 Classic (Carburettor, pre-2005) Maintenance Schedule and Service Intervals

2001-2003 Kawasaki Vulcan 1500 Classic Stock Image

This is the maintenance schedule with associated service intervals for the Kawasaki Vulcan 1500 Classic that was carburettor fed.

Before the Kawasaki Vulcan 1500 FI range, the Kawasaki Vulcan 1500 Classic was fed by a single carburettor.

For a few years, the Vulcan 1500 was sold alongside the 1500 FI. They had the same capacity engine, but changes went beyond fuelling… the motorcycles had different frames and significant other body parts. It’s quite confusing and, in retrospect, entirely unnecessary. C’mon, Kawasaki!

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Maintenance Schedule for Kawasaki Vulcan 1500 Classic

Below is the maintenance schedule for the Kawasaki Vulcan 1500 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.

The maintenance for the Kawasaki Vulcan 1500 Classic is broken into two sections: Emission Related, and Non-Emission Related.

Notes:

  • For higher odometer readings, repeat at the frequency interval established here
  • K: Should be serviced by an authorized Kawasaki dealer
  • †: Replace. add. adjust, or torque if necessary.
  • #: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
  • (Cal): California model only
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)
Emission Related:
Idle speed–check †
Throttle grip play–check †
Spark plug–clean and gap †
Air suction valve – check †
Air cleaner element–clean †#
Evaporative emission control system (Cal) – check †
Non-Emission Related:
Brake light switch – check †
Brake pad wear – check †#
KBrake hose, connections – check †
Brake/clutch fluid level – check †month
KBrake/clutch fluid – change2 years
KFuel hose, connections – check
KSteering –check †
Final gear case oil level – check †
Final gear case oil – change
KPropeller shaft joint – lubricate
Nut, bolt, fastener tightness – check †
KSpoke tightness and rim runout – check †
Tire wear – check †
Engine oil – change #6 months
Oil filter – replace
General lubrication – perform
KFront fork oil – change2 years
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
KCoolant filter – cleanyear
KCaliper piston seal and dust seal – replace4 years
KClutch slave cylinder piston seal – repalce4 years

Tyre size and tyre pressure for the Kawasaki Vulcan 1500 Classic

The Kawasaki Vulcan 1500 Classic has the following tyres and tyre sizes standard (tube type):

Front:

  • Size: 130/90-16 67H
    BRIDGESTONE “EXEDRA G703G”
    DUNLOP “D404FN”
  • Size: 130/90 -16 M/C 67H
    PIRELLI “MT66 Front”

Rear:

  • Size: 150/80 B16 71H
    BRIDGESTONE “EXEDRA G702G”
    DUNLOP “D404G”
  • Size: 150/80 -16 M/C 71H
    PIRELLI “MT66”

The manual for the 2001-2003 Kawasaki Vulcan 1500 Classic recommends the following tyre pressures (when cold):

  • Front: 200 kPa/28 psi
  • Rear: 250 kPa/36 psi

General information about the Kawasaki Vulcan 1500 Classic

The Vulcan 1500 Classic has a 1,470 cc liquid-cooled SOHC 50-degree V-twin engine with a single-pin crankshaft paired with a 5-Speed transmission. It has a 27.6-inch (700 mm) seat height, wide handlebar, forward-mounted floorboards.

With a big V-twin engine displacing 90 cubic inches, the Kawasaki Vulcan 1500 Classic gets attention for its looks, technical features, and power.

Each cylinder has sculpted and polished cooling fins that contrast with the black cast engine. The result really catches the eye. The fins are functional in that they cool the engine, but there’s also a radiator hidden between the frame downtubes.

The Vulcan 1500 Classic also has a large airbox crossover tube between the cylinders. This tube increases airflow to the carburettor, a single 40mm Keihin model. A throttle position sensor is connected to the electronic ignition to vary ignition timing according to throttle setting and engine rpm. The result is better engine response and lower fuel consumption.

Each of these big V-twin’s cylinders has four valves actuated by a single overhead cam. Two valve springs are used on all valves to ensure tight valve closure, while hydraulic valve lash adjusters automatically maintain valve clearance for smooth engine performance, reduced noise, and no maintenance. Automatic cam chain tensioners keep cam timing accurate and provide greater reliability with minimal upkeep.

Manual for the Kawasaki Vulcan 1500 Classic (Carburettor)

2001-2003 Kawasaki Vulcan 1500 Classic Maintenance Schedule Screenshot From Manual
User manual screenshot for the 2001-2003 Kawasaki Vulcan 1500 Classic

The above maintenance schedule comes directly from the user’s manual for the 2001-2003 Kawasaki Vulcan 1500 Classic, which is available here.

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