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Fluid Seal Damage Inspection; Dust Seal And Cover Damage Inspection; Piston Cylinder Damage Inspection; Caliper Holder Shaft Wear Inspection - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Install the anti-rattle spring [A] in the caliper body as
Install the piston insulator.
Install the pads.
Wipe up any spilled brake fluid on the caliper with wet

Fluid Seal Damage Inspection

The fluid seal around the piston maintains the proper
pad/disc clearance. If this seal is not satisfactory, pad wear
will increase, and constant pad drag on the disc will raise
brake and brake fluid temperature.
Replace the fluid seal under any of the following condi-
Fluid leakage around the pad.
Brakes overheat.
There is a large difference in left and right pad wear.
The seal is stuck to the piston.
If the fluid seal is replaced, replace the dust seal as well.

Dust Seal and Cover Damage Inspection

Check that the dust seal and covers are not cracked,
worn, swollen, or otherwise damaged.
If they show any damage, replace them.

Piston Cylinder Damage Inspection

Visually inspect the piston and cylinder surfaces.
Replace the cylinder and piston if they are badly scored
or rusty.

Caliper Holder Shaft Wear Inspection

The caliper body must slide smoothly on the caliper holder
shafts. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and con-
stant drag on the disc will raise brake and brake fluid tem-
Check to see if the caliper holder shafts are not badly worn
or stepped, or rubber friction boot are not damaged.
If the shafts and rubber friction boot are damaged, replace
the rubber friction boot and the caliper holder.


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   Also See for Kawasaki EN500 Vulcan 500 LTD

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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