1996-2005 Kawasaki EN500 Vulcan 500 LTD service manual

Product Information

Table of Contents

1. General Information

• Service Information
• Vehicle Identification
• Specifications

2. Fuel System

• Carburetor Adjustment
• Fuel Tank and Tap Service
• Fuel Line Inspection

3. Cooling System

• Radiator Service
• Coolant Replacement
• Thermostat Inspection

4. Engine Top End

• Cylinder Head Removal/Installation
• Valve Clearance Adjustment
• Camshaft Inspection

5. Clutch

• Clutch Operation Inspection
• Clutch Assembly and Disassembly
• Master and Slave Cylinder Service

6. Engine Lubrication System

• Oil and Filter Change
• Oil Pressure Testing
• Oil Pump Service

7. Engine Removal/Installation

• Precautions and Procedures
• Engine Mounting Checks

8. Crankshaft/Transmission

• Crankshaft Inspection
• Transmission Assembly
• Gear Shifting Check and Repair

9. Wheels/Tires

• Wheel Alignment
• Tire Replacement
• Wheel Bearing Inspection

10. Final Drive

• Chain Inspection
• Chain Replacement
• Sprocket Service

11. Brakes

• Brake Fluid Replacement
• Brake Pad Replacement
• Brake Master Cylinder Overhaul

12. Suspension

• Front Fork Maintenance
• Rear Shock Absorber Inspection
• Suspension Adjustment

13. Steering

• Steering Play Adjustment
• Steering Stem Bearings
• Handlebar Inspection

14. Frame

• Frame Inspection
• Paint and Finish Guidelines

15. Electrical System

• Battery Maintenance
• Ignition System Check
• Lighting and Horn Inspection

16. Appendix

• Special Tools
• Torque Specifications
• Wiring Diagrams

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