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Charging System; Alternator Rotor/starter Clutch Removal - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Charging System

Alternator Rotor/Starter Clutch Removal

Remove the engine sprocket cover (see Engine Sprocket
Removal in the Final Drive chapter).
Loosen the left footpeg mounting bolt and let the footpeg
hang down.
Remove the shift pedal.
Remove the circlip and washer from the shift shaft.
Remove the left side cover.
Slide the air cleaner housing.
Disconnect the alternator lead connectors.
Place an oil pan beneath the alternator cover.
Remove the alternator cover bolts [A], Allen bolt [B] and
pull off the alternator cover [C] and gasket. There are two
knock pins in the cover mating surface.
Hold the alternator rotor [A] steady with the flywheel
holder [B], and remove the rotor bolt.
Special Tool - Flywheel Holder: 57001-1313
The rotor bolt has left-handed threads, therefore it must
be turned clockwise in removing.
Using the rotor puller [A], remove the alternator rotor and
starter clutch assembly from the crankshaft. There is a
spacer between the starter clutch sprocket and the alter-
nator rotor. The woodruff key may come out with the al-
ternator rotor and starter clutch assembly.
Special Tool - Rotor Puller, M16/M18/M20/M22 × 1.5: 57001
If the rotor is difficult to remove, turn the puller shaft
using a wrench while tapping [B] the head of the
puller shaft with a hammer. Do not attempt to strike
the grab bar or the alternator rotor itself. Striking
the bar or the rotor can cause the bar to bend or the
magnets to lose their magnetism.
Remove the rollers [A], springs [B], and spring caps [C]
from the starter clutch [D].


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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