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Drive Shaft Assembly - Kawasaki EN500 Vulcan 500 LTD Service Manual

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8-26 CRANKSHAFT/TRANSMISSION
Transmission

Drive Shaft Assembly

Apply engine oil liberally to the drive shaft, gears, bear-
ings and bushing.
Install the drive shaft ball bearing using the bearing driver
[A].
Special Tool - Bearing Driver, 32: 57001-382
Replace any circlips that were removed with new ones.
Always install circlips [A] so that the opening is aligned
with a spline groove [B], and install toothed washers [C]
so that the teeth [D] are not aligned with the circlip opening
[E]. To install a circlip without damage, fit the circlip onto
the shaft expanding it just enough to install it, and use a
suitable gear to push the circlip into place.
When assembling the drive shaft 6th gear bushing [A]
onto the shaft, align its oil hole [B] with the hole in the
shaft.
The drive shaft gears can be identified by size: the small-
est diameter gear is 1st gear, and the largest is 6th. Be
sure that all parts are put back in the correct sequence,
facing the proper direction, and all circlips and washers
are properly in place.
Proper sequence starting with 1st gear (part of drive shaft)
is: 1st gear, 5th gear (face the flat side of the gear to the
right), washer, circlip, 3rd/4th gear (face 3rd gear side to
the right), circlip, toothed washer, bushing (align the oil
hole with the hole in the shaft), 6th gear (face the dogs
to the right), toothed washer, circlip, 2nd gear, spacer,
needle bearing, needle bearing outer race, and plug.
The toothed washer before the bushing has slightly
smaller teeth than the last one.
Install the spacer onto the drive shaft, facing the cham-
fered side to the ball bearing.
Check that each gear spins or slides freely on the drive
shaft without binding.

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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