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Front Fork Assembly - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Front Fork
If the tubes are tight, use a fork outer tube weight.
Mount the front fork outer tube weight [A] on the top of
the outer tube, by fitting the step of the weight to the top
corner of the outer tube.
Holding the inner tube by hand in a vertical position,
stroke the outer tube up and down several times and
pull it down.
Special Tool - Fork Outer Tube Weight: 57001-1218
Remove the oil seal [D], washer [C], outer tube guide
bushing [B] and inner tube guide bushing [A] from the top
of the inner tube.
Remove the cylinder base out of the bottom of the outer

Front Fork Assembly

Replace the following with new ones.
Retaining Ring
Oil Seal
Dust Seal
Guide Bushing (Inner, Outer)
Fork Bottom Allen Bolt Gasket
Fit the inner tube guide bushing in place.
Insert the cylinder unit [A] and short spring into the inner
tube [B].
Install the cylinder base [C] on the end of the cylinder.
Install the cylinder base from its stepped side.
Insert the inner tube, cylinder unit, spring, cylinder base
as a set into the outer tube [D].
Apply a non-permanent locking agent to the Allen bolt.
Stop the cylinder from turning by using the front fork cylin-
der holder handle and hexagon wrench and tighten the
Allen bolt.
Torque - Front Fork Bottom Allen Bolt: 29 N·m (3.0 kgf·m,
22 ft·lb)
Special Tools - Fork Cylinder Holder Handle: 57001-183
Hexagon Wrench, Hex 27: 57001-1375


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