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Right Engine Cover; Clutch Cover Removal; Clutch Cover Installation; Clutch Release Removal - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Table of Contents

Right Engine Cover

Clutch Cover Removal

Drain the engine oil (see Engine Oil Change in the Engine
Lubrication System chapter).
Clutch Cable
Right Footpeg Assembly
Clutch Cover Bolts [A]
Cable Guide [B]
Turn the release lever [C] toward the front as shown, and
remove the clutch cover.

Clutch Cover Installation

Apply silicone sealant to the area [A] where the mating
surface of the crankcase touches the clutch cover gasket.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
Install the knock pins [B], and replace the cover gasket
with a new one.
Tighten the cover bolts.
Torque - Clutch Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)

Clutch Release Removal

Do not pull out the clutch release shaft for clutch cover
Clutch release shaft removal damages the oil seal in
the clutch cover necessitating the oil seal replace-
Slide the dust cover at the clutch cable lower end out of
Loosen the nuts, and slide the lower end of the clutch
cable to give the cable plenty of play.
Loosen the knurled locknut [B] at the clutch lever, and
screw in the adjuster [C].
Line up the slots [A] in the clutch lever, knurled locknut,
and adjuster, and then free the cable from the lever.
Free the clutch inner cable tip from the clutch release
lever [A].
Turn the release lever toward the rear [B] as shown in the
Pull the lever and shaft assembly out of the clutch cover.


Table of Contents

   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