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Inner Tube Inspection - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Table of Contents
Front Fork
When replacing the outer tube guide bushing [A] with a
new one, hold the used guide bushing [B] against the new
one, and tap the used guide bushing with the front fork oil
seal driver [C] until it stops. The slit [D] in the bushing
must face toward the left or right.
Special Tool - Front Fork Oil Seal Driver: 57001-1219
Apply high temperature grease to the oil seal lips.
After installing the washer, install the new oil seal [A] by
using the fork oil seal driver [B].
Install the new retaining ring into the outer tube.
Using the front fork oil seal driver, install the dust seal.
Pour in the type and amount of fork oil specified, and ad-
just the oil level (see Fork Oil Change).
Insert the fork spring, spring seat and spacer.
Check the O-ring at the top plug and replace it with a new
one if it is damaged.
Install the top plug with the O-ring.
Torque - Front Fork Top Plugs: 23 N·m (2.3 kgf·m, 16.5 ft·lb)

Inner Tube Inspection

Visually inspect the inner tube [A], and repair any dam-
Nicks or rust damage can sometimes be repaired by using
a wet-stone to remove sharp edges or raised areas which
cause seal damage .
If the damages is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
If the inner tube is badly bent or creased, replace
Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
Temporarily assemble the inner and outer tubes, and
pump them back and forth manually to check for smooth
If you feel binding or catching, the inner and outer tubes
must be replaced.
A straightened inner or outer fork tube may fall in
use, possibly causing an accident. Replace a badly
bent or damaged inner or outer tube and inspect the
other tube carefully before reusing it.


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