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Transmission Shaft Installation; Transmission Shaft Disassembly - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Transmission Shaft Installation

With a high-flash point solvent, clean off the outer cir-
cumferences of the transmission ball bearings and needle
bearings, and their bearing housings, and wipe dry.
Check to see that the set rings [A] and set pins [B] are in
place in the transmission bearing housings.
Lift up the clutch housing and primary chain, insert the
drive shaft assembly into the clutch housing, and install
the drive shaft assembly in the upper crankcase half.
Install the output shaft assembly in the upper crankcase
The bearing set pins and rings must match properly with
the holes or grooves in the bearing outer races. When
they match properly, there is no clearance [A] between
the crankcase and the bearing outer races.
Assemble the crankcase.
Install the engine.

Transmission Shaft Disassembly

Remove the transmission shaft.
Using the outside circlip pliers to remove the circlips, dis-
assemble the transmission shafts.
Special Tool - Outside Circlip Pliers: 57001-144
The 5th gear [A] on the output shaft has three steel balls
assembled into it for the positive neutral finder mecha-
nism. To remove this gear from the shaft, quickly spin [B]
the shaft in a vertical position while holding the 3rd gear
[C], and pull off the 5th gear upwards.
The ball bearings and collar are press-fit on the transmis-
sion shafts. To remove the bearings [A], use a press or
the bearing puller [B] and bearing puller adapter [C].
Special Tools - Bearing Puller: 57001-135
Bearing Puller Adapter: 57001-317
The output shaft ball bearing, O-ring and collar ought to
be removed together.
No need for the bearing puller adapter at output shaft.


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   Also See for Kawasaki EN500 Vulcan 500 LTD

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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