Kawasaki VULCAN 1600 CLASSIC (2003) [148/575] 90 fuel system dfi
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Kawasaki VULCAN 1600 CLASSIC (2003) [148/575] 90 fuel system dfi

Kawasaki VULCAN 1600 CLASSIC (2003) [148/575] 90 fuel system dfi
3-90 FUEL SYSTEM (DFI)
Throttle Body Assy
Throttle Assy Installation
•
Install the lower air cleaner duct between cylinders.
•
Replace the flange seal [A] with a new one.
•
With a high-flash point solvent, clean off the flange sur-
face of the cylinder head and wipe dry.
•
Install t he flange [B] and the s eal in the direction shown.
Face the ribs [C] of the flange and the smaller diameter
end upwards.
○
The seal should be centered on the flange.
•
Tighten the inlet manifold bolts [D] to a snag fit.
•
First, tighten the throttle assy holder bolts [A], secondly
the inlet manifold bolts [B] to the specified torque.
Front [C]
Torque - Throttle Assy Holder Bolts: 11 N·m (1.1 kg f·m, 95
in·lb)
Inlet Manifold Bolts: 12 N·m (1.2 kgf·m, 104 in·lb)
Right Sp ark Plug Lead Holder Bolts: 9.8 N·m (1.0
kgf·m, 87 in·lb)
•
Install the lower ends of the throttle cables in the throttle
pulley.
Accelerator Cable [A] and Decelerator Cable [B]
•
Run the throttle cables correctly (see Cable, Wire, and
Hose Routing section in the General Information chapter).
•
Stake [C] the cable clip [D] on the throttle cable holder [E].
Rear View [F]
•
Install the lower end of the choke cable in the choke lever.
Non-permanent Locking Agent -
ChokeCablePlateScrew
Torque - Choke Cable Plate Screw: 2.9 N·m (0.30 kgf·m, 26
in·lb)
•
Run the choke cable correctly (see General Information
chapter) and check that the choke knob moves smoothly.
•
Apply a thin coating of grease to t he throttle cable upper
ends.
•
Install the upper ends of the throttle cables in the grip.
•
Fit the projection [A] of the right switch housing into the
hole [B] of the handlebar (front view).
•
Turn the throttle grip and make sure that the throttle valves
move smoothly and return by spring force.
•
Check the throttle grip free play (see Throttle Grip Free
Play Inspection).
WARNING
Operation with an incorrectly routed cable could re-
sult in an unsafe riding condition.

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