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Shift Drum And Fork Removal - Kawasaki EN500 Vulcan 500 LTD Service Manual

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The output shaft gears can be identified by size: the
largest diameter gear is 1st gear, and the smallest is
6th. Be sure that all parts are put back in the correct
sequence and facing the proper direction, and that all
circlips and washers are properly in place.
Proper sequence starting with 2nd gear is: 2nd gear (face
the flat side of the gear to the left), toothed washer, circlip,
6th gear (face the fork groove side to the right), circlip,
toothed washer, bushing (align the oil holes with the holes
in the shaft), 4th gear (face the side with the dog recesses
to the left), 3rd gear (face the side with the dog recesses
to the right), toothed washer, circlip, 5th gear (face the
fork groove side to the left) with steel balls (3), 1st gear
(face the flat side of the gear to the right), spacer, needle
bearing, and needle bearing outer race.
Press the oil seal [A] onto the collar [B] so it is flush with
the end of collar.
Check that each gear spins or slides freely on the output
shaft without binding.

Shift Drum and Fork Removal

Lower Crankcase Half (see Crankcase Splitting)
External Shift Mechanism (see External Shift Mecha-
nism Removal)
Pull out the shift rod [A], and remove the two shift forks
[B] in the lower crankcase half.
Remove the cotter pin [A], and pull out the 3rd/4th shift
fork guide pin [B].
Remove the bolts [A] holding the shift drum ball bearing
Pull out the shift drum [C] slightly, and remove the 3rd/4th
shift fork. Pull the shift drum free from the crankcase.


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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