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Clutch Removal; Clutch Installation - Kawasaki EN500 Vulcan 500 LTD Service Manual

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5-10 CLUTCH
Clutch

Clutch Removal

Drain the engine oil (see Engine Oil Change in the Engine
Lubrication System chapter).
Remove the clutch cover (see Clutch Cover Removal).
Remove the clutch spring bolts [A], washers [B] and
springs.
Remove the clutch spring plate [C] with the thrust ball
bearing [D] and pusher [E].
Remove the friction plates and steel plates.
When loosening the clutch hub self-locking nut [A], use
the clutch holder [B] to keep the clutch hub from turning
as shown.
Special Tool - Clutch Holder: 57001-1243
Remove the clutch hub self-locking nut and washer.
Pull out the clutch hub [A] and thrust washer [B].
The clutch housing can not be removed without major
disassembly work (see Clutch Housing/Primary Chain
Removal in the Crankshaft/Transmission chapter).

Clutch Installation

Install the thrust washer and clutch hub.
Install the washer.
Discard the used clutch hub self-locking nut, and install
a new self-locking nut with the projected side facing out-
ward.
Install the clutch holder to keep the clutch hub from turning
and tighten the clutch hub self-locking nut.
Special Tool - Clutch Holder: 57001-1243
Torque - Clutch Hub Nut: 132 N·m (13.5 kgf·m, 98 ft·lb)
Install the friction plates and steel plates, starting with a
friction plate and alternating them.
NOTE

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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