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Caliper Assembly - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Caliper
To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply com-
pressed air into the caliper, the piston may crush
your hand or fingers.
Remove the dust seal [A] and fluid seal [B].
Remove the caliper holder, shaft rubber friction boot and
dust cover.
Remove the bleed valve [C] and rubber cap [D].
If compressed air is not available, do as follows with the
brake hose connected to the caliper.
Prepare a container for brake fluid and perform the work
above it.
Remove the pads and spring (see Brake Pad Removal).
Pump the brake lever to remove the caliper piston.

Caliper Assembly

Clean the caliper parts except for the pads.
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
Install the bleed valve and rubber cap.
Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)
Replace the fluid seal [A] with a new one.
Apply brake fluid to the fluid seal, and install it into the
cylinder by hand.
Replace the dust seal [B] with a new one if it is damaged.
Apply brake fluid to the dust seal, and install it into the
cylinder by hand.
Apply brake fluid to the outside of the piston, and push the
piston into the cylinder by hand. Take care that neither the
cylinder nor the piston skirt get scratched.
Replace the shaft rubber friction boot [A] and dust cover
[B] with new ones if they are damaged.
Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to
the caliper holder shafts [C] and holder holes [D]. (PBC is
a special high temperature, water-resistant grease).
WARNING
NOTE
CAUTION
BRAKES 11-7

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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