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

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Shift Drum and Fork Installation

Insert the shift drum [A] into the crankcase part way, install
the 3rd/4th shift fork [B] with the longer side [C] facing the
neutral switch, i.e., the longer side goes onto the drum
Push the shift drum in the rest of the way.
Apply a non-permanent locking agent to the threads of
the holding bolts, and tighten them.
Torque - Shift Drum Bearing Holding Bolts: 11 N·m (1.1
kgf·m, 95 in·lb)
Put the shift fork guide pin [A] with the pin hole upward
into the 3rd/4th shift fork. The guide pin rides in the middle
groove of the three shift drum grooves.
Insert a new cotter pin through the 3rd/4th shift fork and
guide pin from the shorter side of the shift fork, and spread
the cotter pin longer side.
Install the washer, spring, gear positioning lever, collar
and nut.
Set the shift drum in the neutral position, that is, fit the
gear positioning lever [A] into the detent [B] on the shift
drum cam [C].
Install the shift shaft.
Apply a little engine oil to the shift rod and shift fork ears.
Insert the shift rod [A], running it through the shift forks
[B], fitting each shift fork guide pin into the shift drum
groove. The shift forks are identical, and must be installed
with their longer sides [C] facing toward the external shift


Table of Contents

   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