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Caliper; Caliper Removal; Caliper Installation; Caliper Disassembly - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Caliper Removal

Drain the brake fluid.
Loosen the banjo bolt [A] at the brake hose lower end,
and tighten it loosely.
Unscrew the caliper mounting bolts [B], and detach the
caliper [C] from the disc.
Unscrew the banjo bolt and remove the brake hose [D]
from the caliper.
If the caliper is to be disassembled after removal and if
compressed air is not available, remove the piston using
the following steps before disconnecting the brake hose
from the caliper.
Remove the pads (see Pad Removal).
Pump the brake lever to remove the caliper piston.
Immediately wash away any brake fluid that spills.

Caliper Installation

Install the caliper and brake hose lower end.
Replace the washers that are on each side of hose fitting
with new ones.
Tighten the caliper mounting bolts and banjo bolt.
Torque - Caliper Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb)
Brake Hose Banjo Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)
Check the fluid level in the brake reservoir, and bleed the
brake line (see Bleeding the Brake Line).
Check the brake for good braking power, no brake drag,
and no fluid leakage.
Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brakes will
not function on the first application of the lever if
this is not done.

Caliper Disassembly

Remove the caliper.
Remove the pads and anti-rattle spring.
Using compressed air, remove the piston.
Cover the caliper opening with a clean, heavy cloth [A].
Remove the piston by lightly applying compressed air [B]
to where the brake line fits into the caliper.


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