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

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11-10 BRAKES

Master Cylinder

Master Cylinder Removal

Disconnect the front brake switch leads [A].
Remove the banjo bolt [B] to disconnect the upper brake
hose end from the master cylinder [C]. There is a flat
washer [D] on each side of the hose fitting.
Remove the clamp bolts [E] and take off the master cylin-
der as an assembly with the reservoir, brake lever, and
brake switch installed.
Immediately wipe up any brake fluid that spills.

Master Cylinder Installation

Apply grease to the extreme end of the clamp bolts.
Install the master cylinder clamp so that the upper mating
surface [A] of the clamp is aligned with the punch mark
[B] on the handlebar.
Tighten the upper clamp bolt first, and then the lower
clamp bolt. There will be a gap at the lower part of the
clamp after tightening.
Torque - Master Cylinder Clamp Bolts: 11 N·m (1.1 kgf·m,
95 in·lb)
Use a new flat washer on each side of the brake hose
Tighten the banjo bolt.
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
Bleed the brake line after master cylinder installation (see
Bleeding the Brake Line).
Check the brake for weak braking power, brake drag, and
fluid leakage.

Master Cylinder Disassembly

Remove the master cylinder from the handlebar.
Remove the reservoir cap and diaphragm, and pour the
brake fluid into a container.
Remove the locknut and pivot bolt, and remove the brake
Push the dust cover out of place, and remove the circlip.
Special Tool - Inside Circlip Pliers: 57001-143
Pull out the piston [A], secondary cup [B], primary cup [C]
and return spring [D].
Do not remove the secondary cup from the piston
since removal will damage it.


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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