Kawasaki VULCAN 1600 CLASSIC (2003) [202/575] 22 engine top end

5-22 ENGINE TOP END

Rocker Case

Rocker Case Removal

•

Remove the engine (see Engine Removal/Installation

chapter).

•

Remove the throttle body assy (see Fuel System (DFI)

chapter).

•

Remove the rocker case covers (see this chapter).

•

Remove the alternator outer cover (see Electrical System

chapter).

•

Remove the timing inspection plug [A] and rotor bolt plug

[B].

Special Tool - Driver-Filler Cap: 57001–1454 [C]

•

Turn the crankshaft counterclockwise [A] and align the “F”

mark (TDC mark for front piston) [B] with the middle of the

notch [C].

•

Remove:

Oil Hose Banjo Bolt [ A]

Oil Hose [B]

•

Remove the camshaft chain tensioner (see C amshaft

Chain Tensioner Removal).

•

Remove the r ocker case bolts [A], smaller nuts [B], and

then larger nuts [C].

•

Using t he pry points [A], take the rocker case out of the

cylinder head.