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Transmission; External Shift Mechanism Removal; External Shift Mechanism Installation - Kawasaki EN500 Vulcan 500 LTD Service Manual

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External Shift Mechanism Removal

Engine Sprocket (see Engine Sprocket Removal in the
Final Drive chapter)
Chain Guard [A]
Neutral Switch Lead Connector [B]
Shift Lever [C]
Place an oil pan beneath the external shift mechanism
cover [A].
Remove the external shift mechanism cover bolts [B].
Pull the cover.
Remove the cover with the shift shaft assembly while
pushing the shift mechanism arm [A].
Remove the nut [A] and take off the gear positioning lever
[B]. The lever has a collar [C], spring [D], and washer.

External Shift Mechanism Installation

The small diameter side of the collar in the gear position-
ing lever must face toward the crankcase.
Tighten the positioning lever nut [A]
Torque - Gear Positioning Lever Nut: 11 N·m (1.1 kgf·m, 95
Check that the return spring pin [B] is not loose.
If it is loose, remove it, apply a non-permanent locking
agent to the threads, and tighten it.
Torque - Return Spring Pin: 20 N·m (2.0 kgf·m, 14.5 ft·lb)
Apply silicone sealant to the area [C].
Replace the cover gasket with a new one.


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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