Kawasaki EN500 Vulcan 500 LTD User manual

Category
Motorcycles
Type
User manual

This manual is also suitable for

EN500
VULCAN 500 LTD
Motorcycle
Service Manual
This quick reference guide will assist
you in locating a desired topic or pro-
cedure.
•Bend the pages back to match the
black tab of the desired chapter num-
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
Quick Reference Guide
General Information 1
j
Fuel System 2
j
Cooling System 3
j
Engine Top End 4
j
Clutch 5
j
Engine Lubrication System 6
j
Engine Removal/Insta llation 7
j
Crankshaft/Transmission 8
j
Wheels/Tires 9
j
Final Drive 10
j
Brakes 11
j
Suspension 12
j
Steering 13
j
Frame 14
j
Electrical System 15
j
Appendix 16
j
LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC bottom dead center PS horsepower
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) ohm(s)
L liter(s)
Read OWNER’S MANUAL before operating.
EMISSION CONTROL INFORMATION
To protect the environment in which we all live, K awasaki has incorporated crankcase emis-
sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of
the United S tates E nvironmental Protection Agency and California Air Resources Board. Addi-
tionally, Kawasaki has incorporated an evaporative emission control system (3) in compliance
with applicable regulations of the California Air Resources Board on vehicles sold in California
only.
1. Crankcase Emission Control System
This system eliminates the release of crankcase vapors into the atmosphere. Instead, the vapors
are routed through an oil separator to the intake side of the engine. While the engine is operating,
the vapors are drawn into combustion chamber, where they are burned along with the fuel and air
supplied by the carburetion system.
2. Exhaust Emission Control System
This system reduces the amount of pollutants discharged into the atmosphere by the exhaust
of this motorcycle. The fuel and ignition systems of this motorcycle have been carefully des
igned
and constructed to ensure an efficient engine with low exhaust pollutant levels.
3. Evaporative Emission Control System
Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere. In
-
stead, fuel vapors are routed into the running engine to be burned, or stored in a c anister when
the engine is stopped. Liquid fuel is caught by a vapor separator and returned to the fuel tank.
The Clean Air Act, which is the Federal law covering motor vehicle p
ollution, contains what is
commonly referred to as the Act’s “tampering provisions.”
“Sec. 203(a) The following acts and the causing thereof are prohibited...
(3)(A) for any person to remove or render inoperative any device or e
lement of design installed
on or in a m otor vehicle or motor vehicle engine in compliance with regulations under this
title prior to its sale and delivery to the ultimate purchaser, or for any manufacturer or dealer
knowingly to remove or render inoperative any such device or el
ement of design after such
sale and delivery to the ultimate purchaser.
(3)(B) for any person engaged in the business of repairing, servicing, selling, leasing, or trading
motor vehicles or motor vehicle engines, or who operates a fle
et of motor vehicles know-
ingly to remove or render inoperative any device or element of design installed on or in a
motor vehicle or motor vehicle engine in compliance with regulations under this title follow-
ing its sale and delivery to the ultimate purch
aser...”
NOTE
The p hrase “remove or render inoperative any device or element of design” has b een generally
interpre ted as follows:
1. Tampering does not include the temporary removal or rendering inoperative of de-
vices or elements of design in order to perform maintenance.
2. Tampering could include:
a.Maladjustment of vehicle components such that the emission standards are ex-
ceeded.
b.Use of replacement parts or accessories which adversely affect the performance
or dura bility of the motorcycle.
c.Addition of components or accessories that result in the vehicle exceeding the stan-
dards.
d.Permanently removing, disconnecting, or rendering inoperative any component or
element of design of the emission control systems.
WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDER AL LAW,
THE VIOLATION OF WHICH IS PUN ISHA BLE BY CIVIL PENALTIES NOT EXCEEDING
$10,000 PER VIOLATION.
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED
Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering
inoperative by any person other than for purposes of maintenance, repair, or replacement, of any
device or element of design incorporated into any new vehicle for the purpose of noise control
prior to i ts sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the
vehicle after such device or element of design has been removed or r endered inoperative by
any person.
Among those acts presumed to constitute tampering are the acts listed below:
Replacement of the original exhaust system or muffler with a component not in compliance
with Federal regulations.
Removal of the muffler(s) or any internal portion of the muffler(s).
Removal of the air box or air box cover.
Modifications to the muffler(s) or air intake system by cutting, drilling, or other means if such
modifications result in increased noise levels.
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in-
formation to make it useful to the owner who de-
sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting work, and then do the work ca
re-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision m easurem
ents
can only be made if the proper instruments are
used, and the use of s ubstitute tools may ad-
versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in
accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void
the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and
genuine Kawasaki Mo-
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki moto
rcycles are introduced by the
Service Manual. Genuine parts provided as
spare parts are listed in the Parts Catalog.
Follow the p
rocedures in this manual care-
fully. Don’t take shortcuts.
Remember to keep complete records of main-
tenance a
nd repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into its
major systems and these systems make up the
manual’s chapters.
The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
For example, if you want ignition coil informa-
tion, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chap-
ter to find the ignition coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures w hich, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures w hich, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) whi
ch will
help you distinguish different types of informa-
tion.
NOTE
This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
done.
Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the te
xt of a NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the proced
ural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system com
ponents follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec-
ified tighten
ing torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
1
General Information
Table of Con tents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-5
General Specifications (EN500-C1 C6F Models)................................................................ 1-6
General Specifications (EN500C7F Model )......................................................................... 1-9
Periodic Maintenance Chart ................................................................................................... 1-12
Torque and Locking Agent...................................................................................................... 1-16
Unit Conversion Table ............................................................................................................ 1-21
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the items that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following
(1) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten
the life of the motorcycle. For the same reason, before installing a new part, clean off any dust or
metal filings.
(2) B attery Ground
Disconnect the ground (–) cable from the battery before performing any disassembly operations
on the motorcycle. This prevents the engine from accidentally turning over while work is being
carried out, sparks from being generated while disconnecting the cables from electrical parts, as
well as damage to the electrical parts themselves. For reinstallation, first connect the positive
cable to the positive (+) terminal of the battery
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. However, if instal-
lation or assembly sequence is given in this Service Manual, follow it. Note parts locations and
cable, wire, and hose routing during r emoval or disassembly so they can be installed or assem-
bled in the same way. It is preferable to mark and record the l ocations and routing whenever
possible.
(4) Tightening Sequence
When installing bolts, nuts, or screws for which a tightening sequence i s given in this Service
Manual, m ake sure to follow the sequence. When installing a part with several bolts, nuts, or
screws, start them all in their holes and tighten them to a snug fit, thus ensuring t hat the part has
been installed in its proper location. Then, tighten them to the specified t orque in the tightening
sequence and method indicated. If tightening sequence instructions are not given, tighten them
evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws
that are retaining the part a 1/4-turn before removing them.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. Use a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removing screws held by non-permanent locking
agent) in order to avoid damaging the screw heads.
(7) E dges
Watch for sharp edges, as they could cause i njury through careless handling, especially during
major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine
or turning it over.
(8) H igh-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent com-
monly available in North America is standard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(9) Gasket, O-ring
Replace a gasket or an O -ring with a new part when disassembling. Remove any foreign matter
from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent
oil or compression leaks.
GENERAL INFORMATION 1-3
Before Servicing
(10) Liquid Gasket, Locking Agent
Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used.
Apply them sparingly. Excessive amount may block engine oil passages and cause serious dam-
age.
(11)Press
When using a press or driver to install a part such as a wheel bearing, apply a small amount of
oil to the area where the two parts come in contact to ensure a smooth fit.
(12) Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any
ball or needle bearings that were removed with new ones. I nstall bearings with the manufacturer
and size marks facing out, applying pressure evenly with a suitable driver. Apply force only t o the
end of the r ace that contacts the press fit portion, and press it evenly over the base component.
(13) Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally dam-
ages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a
force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless
instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks,
press it in with the marks facing out.
(14) Circlip, Retaining Ring, and Cotter Pin
When installing circlips and retaining rings, take c are to compress or expand them only enough
to install them and no more. Install the circlip with its chamfered side facing load side as well.
Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as re-
moval weakens and deforms them. If old ones are reused, they could become detached while
the motorcycle is driven, leading to a major problem.
(15) Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the sliding
surfaces have an adequate lubricative f ilm. During assembly, make sure to apply oil to any sliding
surface or bearing that has been cleaned. O ld grease or dirty oil could have lost its lubricative
quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off
and apply fresh grease or oil. Some oils and greases in particular should be used only in certain
applications and may be harmful if used in an application for which they are not intended.
(16) Direction of Engine Rotation
To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Pos-
itive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper
adjustment, it i s furthermore necessary to rotate the engine in the direction of positive rotation as
well.
(17) Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed.
Replacement parts will be damaged or lose their original function once they are removed. There-
fore, always replace these parts with new ones every time they are removed. Although the pre-
viously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and
cotter pin have not been so designated in their respective text, they are replacement parts.
(18) Electrical Leads
All the electrical leads are either one-color or two-color. A two-color lead is identified first by
the primary color and then the stripe color. For example, a yellow lead with thin red stripes is
referred to as a “yellow/red” lead; it would be a “red/yellow” lead if the colors were reversed.
Unless instructed otherwise, electrical leads must be connected to leads of the same color.
1-4 GENERAL INFORMATION
Before Servicing
Two-C olor Electrical
(19) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(20) S pecifications
Specification terms are defined as follows:
“Standards” show dimensions or performances which brand-new parts or systems have.
“Service Limits” indicate the usable limits. If the measurement shows excessive wear or deteri-
orated performance, replace the dam aged parts.
GENERAL INFORMATION 1-5
Model Identification
1-6 GENERAL INFORMATION
General Specifications (EN500-C1 C6F Models)
Items EN500-C1 C5 EN500-C6 C6F
Dimensions
Overall Length 2 320 mm (91.3 in.)
Overall Width 830 mm (32.7 in.)
Overall Height 1 125 mm (44.3 in.)
Wheelbase 1 595 mm (62.8 in.)
Road Clearance 120 mm (4.92 in.)
Seat Height 715 mm (31.5 in.)
Dry Weight 199 kg (438 lb) (CAL) 199.5 kg (440 lb)
Curb Weight:
Front 95 kg (209 lb)
Rear 119 kg (262 lb) (CAL) 119.5 (263 lb)
Fuel Tank Capacity 15.0 L (3.9 US gal)
Performance
Minimum Turning Radius 2.8 m (9.2 ft)
Engine
Type
4-stroke, DOHC, 2-cylinder
Cooling System
Liquid-cooled
Bore And Stroke 74.0 × 58.0 mm (2.9 × 2.3 in.)
Displacement 498 cm³ (30.4 cu in.)
Compression Ratio 10.2
Maximum Horsepower 34 kW (46 PS) @8 000 r/min (rpm),
(CH, DE) 25 kw (34 PS) @7 000 r/min (rpm),
(FR) 33 kw (45 PS) @8 000 r/min (rpm)
(US)
Maximum Torque 45 N·m (4.6 kgf·m, 33 ft·lb)
@6 000 r/min (rpm),
(CH, DE) 39 N·m (4.0 kgf·m, 29 ft·lb)
@4 200 r/min (rpm), (US)
Carburetion System Carburetors, Keihin CVK32 × 2
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Timing Advance Electronically advanced
Ignition Timing
From 10° BTDC @1 300 r/min (rpm) to
35° B TDC @8 000 r/min (rpm)
Spark Plugs NGK DR9EA or ND X27ESR-U
or NGK DR8EA or ND X24ESR-U
Cylinder Numbering Method Left to right, 1-2
Firing Order 1-2
Valve Timing:
Inlet:
Open 27° BTDC
Close 47° ABDC
Duration 254°
Exhaust:
Open 52° BBDC
Close 22° ATD C
GENERAL INFORMATION 1-7
General Specif ications (EN500-C1 C6F Models)
Items EN500-C1 C5 EN500-C6 C6F
Duration 254°
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Grade SE, SF or SG class API SE, SF or SG
API SH or SJ with
JASO MA
Viscosity SAE10W-40, 10W-50, 20W-40, or 20W-50 SA E10W-40
Capacity 3.4 L (3.59 US qt)
Drive Train
Primary Reduction System:
Type Chain
Reduction Ratio 2.652 (61/23)
Clutch Type Wet multi disc
Transmission
Type
6-speed constant mesh, return shift
Gear Ratios:
1st 2.571 (36/14)
2nd 1.722 (31/18)
3rd 1.333 (28/21)
4th 1.125 (27/24)
5th 0.961 (25/26)
6th 0.851 (23/27)
Final drive system
Type Chain drive
Reduction Ratio 2.625 (42/16)
Overall Drive Ratio 5.930 @ Top gear
Frame
Type Tubular, double cradle
Caster (Rake Angle) 33°
Trail 151 mm (5.9 in.)
Rim Size:
Front 19 MC × MT 2.15
Rear 15 MC × MT 3.00
Front Tire:
Type Tube
Size 100/90-19 57S (C6 C7)
100/90-19 M/C
57S (C8 )
Rear Tire:
Type Tube
Size 140/90-15 M /C 70S
Front Suspension:
Type Telescopic fork
Wheel Tr avel 150 mm (5.9 in.)
1-8 GENERAL INFORMATION
General Specifications (EN500-C1 C6F Models)
Items EN500-C1 C5 EN500-C6 C6F
Rear Suspension:
Type Swing arm
Wheel Travel 100 mm (3.9 in.)
Brake Type:
Front Single disc
Rear Drum
Electrical Equipment
Battery 12 V 12 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 60/55 W (quartz-halogen)
Tail/brake Light 12 V 8/27 W
(AT, CH, EUR, DE, FR, GR, IT, KR, NL, NO,
ES, SE, GB)
12 V 5/21 W
12 V 5/21 W
Alternator:
Type Three-phase AC
Rated Output 17 A @6 000 r/min (rpm), 14 V
Specifications subject to change without notice, and may not apply to every country.
AT: A ustria Model
CA: Canada Model
CAL: California Model
CH: Switzerland Model
DE: Germ any Model
ES: Spain Model
EUR: E urope Model
FR: F rance Model
GB: United Kingdom Model
GR: Greece Model
IT: Italy Model
KR: K orea Model
NL: Netherlands Model
NO: Norway Model
SE: S weden Model
US: United States Model
GENERAL INFORMATION 1-9
General Specifications (EN500C7F Model )
Items EN500C7F
Dimensions
Overall Length 2 320 mm (91.3 in.)
Overall Width 830 mm (32.7 in.)
Overall Height 1 125 m m (44.3 in.)
Wheelbase 1 595 m m (62.8 in.)
Road Clearance 120 mm (4.92 in.)
Seat Height 715 mm (31.5 in.)
Dry Weight 199 kg (438 lb) ( CAL) 199.5 kg (440 lb)
Curb Weight:
Front 95 kg (209 lb)
Rear 119 kg (262 lb) (CAL) 119.5 (263 lb)
Fuel Tank Capacity 15.0 L (3.9 US gal)
Performance
Minimum Turning Radius 2.8 m (9.2 ft)
Engine
Type 4-stroke, DO HC, 2-cylinder
Cooling System Liquid-cooled
Bore And Stroke 74.0 × 58.0 mm (2.9 × 2.3 in.)
Displacement 498 cm³ (30.4 cu in.)
Compression Ratio
10.2
Maximum Horsepower
34 kW (46 PS) @8 000 r/min (rpm),
(US)
Maximum Torque 45 N·m (4.6 kgf·m, 33 ft·lb)
@6 000 r/min (rpm),
Carburetion System Carburetors, Keihin CVK32 × 2
Starting System Electric starter
Ignition System Battery and coil (transistorized)
Tim ing Advance Electronically advanced
Ignition Timing
From 10° BTDC @1 300 r/min (rpm) to
35° BTDC @8 000 r/min (rpm)
Spark Plugs NGK DR9EA or ND X27ESR-U
or NGK DR8EA or ND X 24ESR-U
Cylinder Numbering Method Left to right, 1-2
Firing Order 1-2
Valve Timing:
Inlet:
Open 27° BTDC
Close 47° ABDC
Duration
254°
Exhaust:
Open 52° BBDC
Close 22° ATD C
Duration 254°
1-10 GENERAL INFORMATION
General Specifications (EN500C7F Model )
Items EN500C7F
Lubrication System Forced lubrication (wet sump)
Engine Oil:
Grade API SE, SF or SG class
API SH, SJ or SL with JASO MA
Viscosity
SAE10W-40
Capacity 3.4L(3.59USqt)
Drive Train
Primary Reduction System:
Type Chain
Reduction Ratio 2.652 (61/23)
Clutch Type Wet multi disc
Transmission
Type 6-speed constant mesh, return shift
Gear Ratios:
1st 2.571 (36/14)
2nd
1.722 (31/18)
3rd
1.333 (28/21)
4th
1.125 (27/24)
5th 0.961 (25/26)
6th 0.851 (23/27)
Final drive system
Type Chain drive
Reduction Ratio 2.625 (42/16)
Overall Drive Ratio 5.930 @ Top gear
Frame
Type Tubular, double cradle
Caster (Rake Angle) 33°
Trail 151 mm (5.9 in.)
Rim Size:
Front 19 MC × MT 2.15
Rear 15 MC × MT 3.00
Front Tire:
Type Tube
Size 100/90-19 M/C 57S
Rear Tire:
Type Tube
Size 140/90-15 M/C 70S
Front Suspension:
Type Telescopic f ork
Wheel Travel 150 mm (5.9 in.)
Rear Suspension:
Type Swing arm
Wheel Travel 100 mm (3.9 in.)
GENERAL INFORMATION 1-11
General Specifications (EN500C7F Model )
Items EN500C7F
Brake Type:
Front
Single disc
Rear Drum
Electrical Equipment
Battery 12 V 12 Ah
Headlight:
Type Semi-sealed beam
Bulb 12 V 60/55 W (quartz-halogen)
Tail/brake Light 12 V 5/21 W
Alternator:
Type Three-phase AC
Rated Output 17 A @6 000 r/min ( rpm), 14 V
Specifications subject to change without notice, and may not apply to every country.
CA: Canada Model
CAL: California Model
US: United States Model
1-12 GENERAL INFORMATION
Periodic Maintenance Cha rt
The scheduled maintenance must be done in accordance with this chart to keep the m otorcycle in
good running condition. The initial m aintenance is vitally important and must not be neglected.
( Other than United States and Canada Models)
FREQUENCY Whichever
comes
first
*ODOMETER
READING
× 1 000 km
1 000 mile)
1 6 12 18 24 30 36
OPERATION
Every
(0.6) (4.0) (7.5) (12) (15) (20) (24)
Carburetor synchronization - inspect
Idle speed - adjust
Throttle grip play - inspect
Spark plug - clean and gap
Valve clearance - inspect
Air suction valve - inspect
Air cleaner element - clean #
Fuel hose, connections - inspect
Battery electrolyte level - inspect 6 month
Brake play - inspect
Brake light switch - inspect
Brake lining or pad wear - inspect †#
Brake fluid level - inspect month
Brake fluid - change 2 years
Brake hose, connections - inspect
Brake master cylinder cup and dust
seal - replace
4 years
Caliper fluid seal and dust s eal - replace 4 years
Brake cable - replace 2 years
Clutch - adjust
Steering - inspect
Drive chain wear - i nspect †#
Drive chain - lubricate # 600 km
Drive chain slack - inspect †# 1000 km
Spoke tightness and rim runout -
inspect
Nut, bolts, and fasteners tightness -
inspect
Tire wear - inspect
Engine oil - change # 6 month
Oil filter - replace
General lubrication - perform #
Front fork oil - change 2 y ears
Front fork oil leak - inspect
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Kawasaki EN500 Vulcan 500 LTD User manual

Category
Motorcycles
Type
User manual
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