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Kawasaki Vulcan 1600 (Classic and Nomad, 2003-2008) Maintenance Schedule and Service Intervals

2007 Vulcan 1600 Classic

This is the maintenance schedule with associated service intervals for the Kawasaki Vulcan 1600 range of motorcycles, including the Classic and Nomad, made between 2001 and 2008 — the VN1600 line.

The Vulcan is Kawasaki’s name for their cruiser, tourer, and bagger range. The Vulcan 1600 is a an update to the Vulcan 1500 FI. While the 1500 engine came in both carburettor-fed and fuel injected forms, the 1600 is all fuel injected.

The Kawasaki Vulcan 1600 range is powered by a 1,552 cc (barely rounds up to 1600!) liquid-cooled SOHC fuel-injected V-twin engine with two spark plugs per cylinder. The motorcycles have five-speed transmissions and shaft drives.

Here are the differences between the motorcycles in the range:

  • Kawasaki Vulcan 1600 Classic (2003-2008): The baseline, classic cruiser. The 1600 Classic was replaced by the 1700 Classic in 2009.
  • Kawasaki Vulcan 1600 Nomad (2005-2008): The version with the touring windscreen and luggage. The engine is otherwise identical.
  • Kawasaki Vulcan 1600 Mean Streak (2004-2008): Tuned for about 3kW/5hp more power (with different cam profiles and fuelling), with more aggressive rake, inverted forks, and different tyres, for sportier handling. The ride is quite different.

The Mean Streak has some different aspects to its maintenance schedule, so I’m keeping it separate.

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What you need to service your Kawasaki Vulcan 1600

Even though it’s a shaft-driven bike, you still have to do regular service on your Vulcan 1600.

Top priority are keeping the fluids changed — coolant, brake/clutch fluid, and gear oil (occasionally).

But thankfully, there’s no chain to maintain!

Here are the general consumables you’ll need to maintain your Kawasaki Vulcan 1600.

PartKawasaki Vulcan 1600 Spec
OilYou need SAE 10W-40 engine oil with API SH or SJ (or newer, e.g., SL or SM) with JASO MA rating, for example Kawasaki 10W-40 Engine Oil, or another high-grade oil like Motul 7100. Some owners (e.g. this thread) like Shell Rotella T6.

Don’t over-torque the drain bolt (spec is 30 Nm/22 lb-ft per the manual) — use a torque wrench if you don’t have experience with how much torque is enough.
Oil filterUse a Hiflofiltro filter for easy replacement, part HF204RC. Torque for oil filter is 18 Nm (13 ft-lb) (use a torque wrench, and it’s easier on the K&N one)
Final drive oilRemember to change this periodically. It’s not hard! Use Mobil 1 Gear Oil, a popular choice.
Brake padsMany riders upgrade to EBC HH brake pads (see this thread). These are the part numbers you need:

Front Left: FA229HH
Front Right: FA231HH
Rear: FA231HH

Brake pad part numbers from EBC catalogue for the VN1600
Spark plugsNGK DPR6EA-9, with a spark plug gap of 0.8-0.9mm (use a spark plug gapping tool), torqued to 18 Nm or 13 ft-lb (use a torque wrench). Remember you need four spark plugs as it’s a twin spark engine.

Kawasaki Vulcan 1600 spark plug screenshot
Air filterMost people replace the OEM air filter with a K&N aftermarket air filter (functionally identical). You can also use the K&N part KA-1603 for the Nomad and Classic.
Brake/Clutch fluidSpec is to use DOT 4 brake/clutch fluid, e.g. Castrol DOT 4.
CoolantUse, as ships with the Vulcan, 50/50 pre-mix of ethylene glycol-based coolant with anti-corrosion inhibitors, e.g. Valvoline Zerex G05
GreaseUse a lithium soap based grease for all the important greasing points.
Consumables for servicing the Kawasaki Vulcan 1600 Nomad and Classic

Maintenance Schedule for Kawasaki Vulcan 1600 motorcycles

Below is the maintenance schedule for the Kawasaki Vulcan 1600. It’s taken straight from the manual for them and adapted to fit a website.

Having shaft drives and fuel injection, maintaining a Vulcan 1600 is a lot easier than it used to be! That said, replace your shaft drive with new gear oil 36,000 km (24,000 mi) or so… it’s surprising how many people don’t. Or if they do, do it with every oil change, obsessively (and unnecessarily).

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

Notes/Legend:

  • For higher odometer readings, repeat at the frequency interval established here
  • Kawasaki recommends items related to brakes, fuel, steering, and fluids be serviced by an authorised dealer.
  • Items marked “Check”: Replace, adjust, or torque if necessary.
  • #: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping
  • The break-in service is omitted.
km x 100061218243036
mi x 100047.512152024Every
Idle speed — check
Throttle control system — check
Spark plug — clean and gap † (replace with DPR6EA-9 if necessary)
Air suction valve — check
Air cleaner element —clean # (replace with KA-1603 if necessary)
Evaporative emission control system — check
Brake/clutch hoses, connections — check
Brake light switch — check
Brake pad wear — check #
Brake/clutch fluid level — check † Month
Brake/clutch fluid — change (use Castrol DOT 4)2 years
Fuel hose, connections — check
Steering — check
Final gear case oil level — check
Final gear case oil — change (use Mobil 1 Gear Oil)
Propeller shaft joint – lubricate
Nut, bolt, fastener tightness — check
Tire wear — check
Engine oil — change (Kawasaki 10W-40 Engine Oil or Motul 7100 10W-40)Year
Oil filter — replace (HF204RC)
General lubrication—- perform (lithium soap-based grease)
Front fork oil leak — check
Rear shock absorber oil leak — check
Swingarm pivot – lubricate
Coolant — change (Valvoline Zerex G05)2 years
Radiator hoses, connections — check
Steering stem bearing — lubricate2 years
Brake/clutch master cylinder cup and dust seal — replace4 years
Caliper piston seal and dust seal — replace4 years
Clutch slave cylinder piston seal — replace4 years
Kawasaki Vulcan 1600 Nomad and Classic maintenance schedule

Tyre size and tyre pressure for the Kawasaki Vulcan 1600

The Kawasaki Vulcan 1600 Classic and Nomad ship with Bridgestone Exedra or Dunlop D404 tyres.

The Kawasaki Vulcan 1600 motorcycles (Classic and Nomad) have following tire sizes standard (tubeless type):

WheelSizePressure
Front130/90-16 M/C 67H200 kPa/28 psi
Rear 170/70 B16 M/C 75H250 kPa/36 psi
Kawasaki Vulcan 1600 Motorcycle Tyre Specs

Be aware that the Mean Streak has different tyre specs. Don’t get the wrong ones!

General information about the Kawasaki Vulcan 1600 Nomad and Classic

The Kawasaki Vulcan 1600 range of motorcycles were another upgrade to the Vulcan 1500. They got a bigger engine, standard fuel injection (which as standard on the last 1500s, but not the earlier ones), and a number of other changes to improve overall rideability.

Like most big Kawasaki cruisers, the Kawasaki Vulcan 1600 is a very relaxing motorcycle to ride, whether in Classic or Nomad form. The A 95-cubic inch V-twin engine makes a ton of plenty of low-end torque, with more than enough power for just about anything. It’s not a slow bike — the smoothness of the twin is deceptive and you can easily find yourself doing well above legal speeds.

The engine’s power is complemented by its well-functioning 41mm telescopic form and its stout frame, which gives maximum rigidity for really great steering feel, easy side-to-side transitions, and overall very luxurious ride quality. The Vulcan is like a Cadillac on the highway — just smooth.

Even though this is a Japanese or “metric” cruiser, the Vulcan 1600 has lots of elements that make it an American-style classic. Huge amounts of chrome, dual slash-cut mufflers, deep paint, and a multi-reflector headlight are all just iconic design features.

And the Vulcan 1600 has just enough tach to keep you interested including an LCD screen, fuel gauge, and the standard clocks.

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.

Riding the Vulcan 1600 is like a dream. It has unlimited pull. The engine is smooth, but still has enough of a soulful thump (or purr) that the single-pin crank V-twins are known for.

The engine has single overhead cams and hydraulic valve lash adjusters. Together with the automatic cam chain tensioner, the Vulcan 1600 will need very little maintenance.

You should get used to scraping, though. You’ll scrape floorboards all the time — around corners, around roundabouts, or out on the highway. The thing is, it’s fine. The bike is designed to scrape. It’s not begging to be thrown into corners, but when you start pushing it a little harder than it likes, it’ll let you know.

If you’re looking to do some distance, grab the nomad. You’ll appreciate the screen and the standard bags!

Manual for the Kawasaki Vulcan 1600

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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