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Clutch Plate Wear, Damage Inspection; Clutch Plate Warp Inspection - Kawasaki EN500 Vulcan 500 LTD Service Manual

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The grooves [A] on the friction plate surfaces are cut tan-
gentially and radially, install the friction plates so that the
grooves run toward the center in the direction of the clutch
housing rotation (counterclockwise viewed from the en-
gine right side).
If new dry steel plates and friction plates are in-
stalled, apply engine oil to the surfaces of each
plate to avoid clutch plate seizure.
Apply engine oil to the thrust ball bearing.
Apply molybdenum disulfide grease to the rubbing portion
of clutch spring plate pusher.
Tighten the clutch spring bolts.
Torque - Clutch Spring Bolts: 9.3 N·m (0.95 kgf·m, 82 in·lb)

Clutch Plate Wear, Damage Inspection

Visually inspect the friction and steel plates for signs of
seizure, overheating (discoloration), or uneven wear.
If any plates show signs of damage, replace the friction
plates and steel plates as a set.
Measure the thickness of the friction plate [A] at several
If any of the measurements is less than the service limit,
replace the friction plate.
Friction Plate Thickness
2.9 ∼ 3.1 mm (0.1142 ∼ 0.1220 in.)
Service Limit:
2.75 mm (0.108 in.)

Clutch Plate Warp Inspection

Place each friction plate or steel plate on a surface plate,
and measure the gap between the surface plate [A] and
each friction plate or steel plate [B] with a thickness gauge
[C]. The gap is the amount of friction or steel plate warp.
If any plate is warped over the service limit, replace it with
a new one.
Friction and Steel Plate Warp
less than 0.2 mm (0.008 in.)
Service Limit:
0.3 mm (0.012 in.)


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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