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Output Shaft Assembly - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Output Shaft Assembly

Assembly is the reverse of disassembly. Note the follow-
Apply engine oil liberally to the output shaft, gears, bear-
ings, bushing and O-ring.
Install the output shaft ball bearing, O-ring and collar us-
ing the bearing driver.
Special Tool - Bearing Driver, 32: 57001-382
The ball bearing, O-ring and collar ought to be installed
Replace any circlips that were removed with new ones.
Always install circlips so that the opening is aligned with
a spline groove. To install a circlip without damage, fit the
circlip onto the shaft expanding it only enough to install it,
and use a suitable gear to push the circlip into place.
[A] Circlip
[B] Toothed Washer
When assembling the output shaft 3rd/4th gear bushing
[A] to the shaft, align its oil holes [B] with the holes in the
When installing the 5th gear and steel balls on the
output shaft, do not apply grease to the balls to hold
them in place. This will cause the positive neutral
finder mechanism to malfunction.
Fit the steel balls into the 5th gear holes in the output shaft
as shown.
Gear (5th) [A]
Shaft [B]
Steel Balls [C]
Check the effect of ball-locking that the 5th gear [A] does
not come out of the output shaft when moving it up and
down by hand.


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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