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Front Fork Disassembly - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Front Fork

Front Fork Disassembly

Loosen the upper clamp Allen bolt.
Loosen the fork top plug.
Remove the front fork leg (see Front Fork Removal).
Remove the top plug with the O-ring, spacer, spring seat,
and spring (see Fork Oil Change).
Pour out the fork oil (see Fork Oil Change).
Turn the fork upside down, and force out the oil by
Hold the outer tube horizontally in a vice.
Stop the cylinder [A] from turning by using the front fork
cylinder holder handle [B] and hexagon wrench [C].
Special Tools - Fork Cylinder Holder Handle: 57001-183
Hexagon Wrench, Hex 27: 57001-1375
Unscrew the Allen bolt [D] and take off the bolt and gasket
from the bottom of the outer tube.
Remove the piston cylinder unit [A] and short spring [B]
from the inner tube.
Separate the inner tube from the outer tube as follows.
Remove the dust seal [A] from the outer tube.
Remove the retaining ring [B] from the outer tube.
Grasp the inner tube and stroke the outer tube up and
down several times. The shock to the fork seal separates
the inner tube from the outer tube.


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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