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Crankcase Splitting
Tighten the lower crankcase-half bolts using the following
3 steps:
Tighten all lower crankcase-half bolts to a snug fit.
Following the sequence numbers on the lower crankcase
half, torque the 8 mm bolts first to about one half of the
specification, and finally to the specification in the same
Torque Value for 8 mm Bolts
14 N·m (1.4 kgf·m, 10.0 ft·lb)
27 N·m (2.8 kgf·m, 20 ft·lb)
Tighten the 6 mm bolts.
Torque - Crankcase 6 mm Bolts: 12 N·m (1.2 kgf·m, 104
Check that the O-ring [A] of the breather return pipe is in
good condition.
If it is damaged, replace it with a new one.
Apply a small amount of oil to the O-ring.
Fit the breather return pipe [B] into the passage in the
upper crankcase half.
Install the main oil pipe connecting pipe [A] and oil pump
outer pipe [B].
Check that the O-rings are in good condition.
If they are damaged, replace them with new ones.
Apply a small amount of oil to the O-rings. The positioning
hole in the connecting pipe must fit to the boss on the
lower case.
Apply a non-permanent locking agent to the threads of
the oil outer pipe mounting bolt.
Install the oil screen.
Install the oil pan (see Oil Pan Installation in the Engine
Lubrication chapter).
Turn the engine over so it is upright.
Put the 8 mm bolts [A], and the 6 mm bolts [B] into the
upper crankcase half as shown in the figure, torque the 8
mm bolt first, then the other bolts in the sequence shown.
Torque - Crankcase 8 mm Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb)
Crankcase 6 mm Bolts: 12 N·m (1.2 kgf·m, 104
After tightening all crankcase bolts, check the following
Drive shaft and output shaft turn freely.
While spinning the output shaft, gears shift smoothly from
the 1st to 6th gear, and 6th to 1st.
When the output shaft stays still, the gear can not be
shifted to 2nd gear or other higher gear positions.


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