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Alternator Rotor/starter Clutch Installation - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Charging System
Holding the rotor [A] steady, remove the Allen bolts [B] to
separate the rotor and starter clutch [C].

Alternator Rotor/Starter Clutch Installation

Apply a non-permanent locking agent to the threads of the
starter clutch Allen bolts, and tighten them to the specified
torque in assembling the starter clutch onto the alternator
Torque - Starter Clutch Allen Bolts: 34 N·m (3.5 kgf·m, 25
Be careful that the rollers do not drop out of the starter
clutch during assembly.
Using a high-flash point solvent, clean off any oil or dirt
that may be on the crankshaft taper [A] and rotor tapered
hole [B].
Fit the woodruff key securely in the slot [C] in the crank-
shaft before installing the rotor assembly on the crank-
Tighten the rotor bolt while holding the rotor steady with
the flywheel holder, and turn the rotor bolt counterclock-
wise to install it.
Torque - Alternator Rotor Bolt: 69 N·m (7.0 kgf·m, 51 ft·lb)
Special Tool - Flywheel Holder: 57001-1313
Apply silicone sealant to the area [A] where the mating
surface ends of the crankcase touch the alternator cover
Apply silicone sealant around the circumference of the
wiring grommets before setting it in the notch in the al-
ternator cover.
Check that knock pins [B] are in place on the crankcase.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
Tighten the alternator cover Allen bolt and bolts.
Torque - Alternator Cover Allen Bolt: 13 N·m (1.3 kgf·m, 113
Alternator Cover Bolts: 11 N·m (1.1 kgf·m, 95 in·lb)
Check the engine oil level, and add if necessary (see En-
gine Oil Level Inspection in the Engine Lubrication Sys-
tem chapter).


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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