Kawasaki Vulcan 1500 (1981–2008) maintenance schedule & recalls

ON CERTAIN 2003 VULCAN 1500 CLASSIC, 1500 DRIFTER, 2003-2004 1500 MEAN STREAK, 2003 1600 CLASSIC, AND 2003-2004 NOMAD FL MODEL MOTORCYCLES, HIGH OIL PRESSURE UPON A COLD START-UP CAN DEFORM THE OIL FILTER CARTRIDGE.

Remedy: DEALERS WILL REPLACE THE OIL FILTER. OWNER NOTIFICATION BEGAN ON FEBRUARY 2, 2004. OWNERS SHOULD CONTACT KAWASAKI AT 1-949-770-0400.

ON CERTAIN MOTORCYCLES, ACCELERATOR PUMP DIAPHRAGMS MAY BE DAMAGED FROM EXCESSIVE ASSEMBLY CLAMPING PRESSURE, WHICH CAN ALLOW FUEL TO LEAK FROM THE PUMP ACTUATING ROD AREA.

Remedy: DEALERS WILL REPLACE THE ACCELERATOR PUMP DIAPHRAGM. OWNER NOTIFICATION BEGAN ON JANUARY 20, 2004. OWNERS SHOULD CONTACT KAWASAKI AT 1-949-770-0400.

VEHICLE DESCRIPTION: MOTORCYCLES. THE FUEL HOSE FROM THE FUEL FILTER TO THE THROTTLE ASSEMBLY CAN RUB AGAINST THE BOTTOM OF THE FUEL PUMP PLATE AND DEVELOP A LEAK.

Remedy: DEALERS WILL REPLACE THE FUEL HOSE WITH A MOLDED HOSE THAT CURVES AWAY FROM THE FUEL PUMP PLATE. ALSO, A NEW BRACKET AND GROMMET WILL BE ADDED TO HOLD THE NEW HOSE IN POSITION. THE FUEL RETURN HOSE WILL ALSO BE REPLACED.

VEHICLE DESCRIPTION: MOTORCYCLES (VN1500-J1/L) EQUIPPED WITH A DIGITAL FUEL INJECTION SYSTEM AND A VEHICLE-DOWN SENSOR. THIS FEATURE IS DESIGNED TO PREVENT THE FUEL INJECTION SYSTEM FROM CONTINUING TO PUMP FUEL IF THE MOTORCYCLE FALLS DOWN, BY SHUTTING OFF THE IGNITION AND FUEL INJECTION PUMP. DURING BATTERY MAINTENANCE, THE VEHICLE-DOWN SENSOR CAN BE DISLODGED FROM ITS NORMAL MOUNTED POSITION. IF THE SENSOR IS OUT OF POSITION, THE MOTORCYCLE MAY NOT START OR MAY STALL DURING CERTAIN DRIVING MANEUVERS.

Remedy: DEALERS WILL INSPECT FOR PROPER MOUNTING OF THE SENSOR AND RE-INSTALL IF IT IS NOT IN THE CORRECT POSITION. DEALERS WILL ALSO AFFIX TO THE MOTORCYCLE FRAME, A WARNING LABEL THAT PROVIDES INSTRUCTIONS ON REPOSITIONING THE VEHICLE-DOWN SENSOR AFTER SERVICING THE BATTERY.

VEHICLE DESCRIPTION: MOTORCYCLES. AN IMPROPERLY MANUFACTURED TRANSMISSION GEAR CAN CAUSE WEAKENING AND EVENTUAL BREAKAGE OF AN ADJACENT GEAR.

Remedy: DEALERS WILL INSPECT THESE MOTORCYCLES AND REPAIR AFFECTED UNITS.

PRESSURE ON THE BATTERY GROUND LEAD (THE CRIMPED AND SOLDERED TERMINATION OF THE BATTERY CABLE) FROM THE BASE OF THE OPERATOR'S SEAT CAN CAUSE THE BATTERY TERMINAL TO SHORT OUT INSIDE THE BATTERY.

Remedy: DEALERS WILL REPLACE THE EXISTING BATTERY CABLES WITH A NEWLY DESIGNED CABLE AND INSPECT THE BATTERY TO VERIFY THAT NO DAMAGE HAS OCCURRED.

THE DRIVE CHAINS HAVE BEEN IMPROPERLY HEAT-TREATED DURING THE MANUFACTURING PROCESS. EXPOSURE TO CORROSIVE CONDITIONS CAN CAUSE THE CHAIN SIDE PLATES TO CRACK AND ULTIMATELY FAIL.

Remedy: DEALERS WILL REPLACE THE DRIVE CHAINS ON THE MOTORCYCLES INVOLVED IN THIS RECALL.

ON CERTAIN MOTORCYCLES, CONTAMINATED FUEL USED DURING THE FINAL ENGINE INSPECTION PROCESS MAY HAVE CAUSED DETERIORATION OF THE CARBURETOR ACCELERATOR PUMP DIAPHRAGM, WHICH COULD LEAD TO FUEL LEAKAGE FROM THE ACCELERATOR PUMP CHAMBER.

Remedy: DEALERS WILL REPLACE THE ACCELERATOR PUMP DIAPHRAGM. OWNER NOTIFICATION BEGAN ON JULY 29, 2003. OWNERS SHOULD CONTACT KAWASAKI AT 1-866-802-9381.