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Cylinder, Piston; Cylinder Removal; Cylinder Installation; Piston Removal - Kawasaki EN500 Vulcan 500 LTD Service Manual

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4-30 ENGINE TOP END

Cylinder, Piston

Cylinder Removal

Remove the cylinder head (see Cylinder Head Removal).
Remove the main oil pipe mounting bolt.
Pull out the water pipe with water pump cover (see Water
Pump Removal in the Cooling System chapter).
Take out the cylinder block so as not to damage the main
oil pipe.

Cylinder Installation

Install:
Dowel Pins [A]
New Cylinder Base Gasket [B]
Apply engine oil to the cylinder bore.
Prepare two auxiliary head bolts with their heads cut.
Install the two bolts [C] diagonally in the crankcase.
Position the crankshaft so that all the piston heads are
almost level.
Install the cylinder block.
Insert the piston rings with your thumbs.

Piston Removal

Remove the cylinder (see Cylinder Removal).
Wrap a clean cloth [A] around the base of each piston to
secure it in position for removal and so that no parts and
dirt will fall into the crankcase.
Remove the piston pin snap rings [B] from the outside of
each piston.
Remove the piston by pushing its piston pin puller out the
side from which the snap ring was removed. Use a piston
pin puller, if the pin is tight.
Special Tool - Piston Pin Puller Assembly [A]: 570001-910
Remove the top and second rings with piston ring pliers.
Special Tool - Piston Ring Pliers: 57001-115
If the special tool is not available, carefully spread the
ring opening with your thumbs and then push up on the
opposite side of the ring [A] to remove it.
Remove the 3-piece oil ring with your thumbs in the same
manner.

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   Also See for Kawasaki EN500 Vulcan 500 LTD

This manual is also suitable for:

Vulcan 500 ltd

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  • Ricardo Paluan Apr 27, 2016 01:22:
    Adquiri recentemen​te uma moto vulcan 500 ano 1995. Tenho o 37 anos e iniciante no mundo motociclis​ta. Entretanto​, em razão só tempo e idade da moto, não tenho o manual do proprietá​rio, sendo este indispens