Kawasaki VULCAN 1600 CLASSIC (2003) [196/575] 16 engine top end

5-16 ENGINE TOP END

Clean Air System

Vacuum Switch Valve Removal

•

Remove:

Fuel Tank (see Fuel System Chapter)

•

Pull off the hoses [A] and take out the vacuum switch

valve [B].

Vacuum Switch Valve Installa tion

•

Install the vacuum switch valve [A] so that the inlet vac-

uum hose [B] faces rear side.

•

Route the hoses correctly (see General Information chap-

ter).

Vacuum Sw itch Valve Operation Test

•

Pull the vacuum switch hose [A] out of the right air cleaner

base.

•

Start the engine and run it at idle speed.

•

Plug the vacuum switch hose end with your finger and feel

vacuum pulsing in the hose.

If there is no vacuum pulsation, check the hose line for

leak. If there is no leak, check the vacuum switch valve

(see Vacuum Switch Valve Unit Test).

•

Apply a soap and water solution or rubber lubricant to

the end of the vacuum switch hose [A] and put the hose

into the right air cleaner base [B] with the white m ark [C]

faced forward until the white mark aligns with the t op of

the grommet [D].

Vacuum Switch Valve Unit Test

•

Remove the vacuum switch valve (see Vacuum Switch

Valve Removal).

•

Connect a commercially available vacuum gauge [A] and

syringe [B] (or fork oil level gauge) to the vacuum hoses

as shown.

Special Tool - Fork Oil Level Gauge: 57001-1290

Air Flow [C]