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Crankcase Splitting - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Crankcase Splitting

Crankcase Splitting
Remove the engine (see Engine Removal in the Engine
Removal/Installation chapter).
Set the engine on a clean surface and hold the engine
steady while parts are being removed.
Shift Lever (see External Shift Mechanism Removal)
Starter Motor (see Starter Motor Removal in the Electri-
cal System chapter)
Water Pump (see Water Pump Removal in the Cooling
System chapter)
Clutch Cover (see Clutch Cover Removal in the Clutch
Remove the following parts only if the crankshaft is to be
Cylinder Head, Cylinder and Pistons (see Cylinder
Head, Cylinder, Piston Removal in the Engine Top End
Starter Clutch Sprocket (see Alternator Rotor, Starter
Clutch Removal in the Electrical System chapter)
Clutch (see Clutch Removal in the Clutch chapter)
Remove the 6 mm upper crankcase-half bolts [A] first, and
then the 8 mm bolt [B].
Turn the engine upside down and remove the following
Oil Pan (see Oil Pan Removal in the Engine Lubrication
System chapter)
Oil Pump Outer Pipe (see Oil Pump Removal in the En-
gine Lubrication System chapter)
Main Oil Pipe Connecting Pipe
Remove the 6 mm lower crankcase-half bolts [A] first, and
then the 8 mm bolts [B] in the reverse order of installation
sequence (see Crankcase Assembly).
Pull the breather return pipe out of the crankcase and
leave it in place temporarily.
Pry the points [A] indicated in the figure to split the
crankcase halves apart, and remove the lower crankcase
half. There are two knock pins at the front and rear of the


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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