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Alternator Stator Removal; Alternator Stator Installation; Regulator/rectifier Removal; Regulator/rectifier Output Voltage Inspection - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Table of Contents
Charging System

Alternator Stator Removal

To keep the loss of engine oil to a minimum, set the
motorcycle vertically.
Remove the alternator cover (see Alternator Rotor and
Starter Clutch Removal).
Remove the screws [A] and the holding plate [B] for the
stator wiring.
Unscrew the Allen bolts [C] and remove the stator [D].
Remove the grommet for the crankshaft sensor lead.

Alternator Stator Installation

Apply silicone sealant [A] around the circumference of the
wiring grommets before setting them in the notch in the
alternator cover.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
Install the grommet for the stator wiring and crankshaft
sensor lead in this order.
The stator wiring has to be installed along the alter-
nator cover without rising away from its surface. If
the wires touch the rotor, they will be damaged.
Tighten the Allen bolts.
Torque - Alternator Stator Allen Bolts: 12 N·m (1.2 kgf·m,
104 in·lb)
Alternator Lead Clamp Screws: 2.9 N·m (0.30
kgf·m, 26 in·lb)

Regulator/Rectifier Removal

Remove the left side cover (see Left Side Cover Removal
in the Frame chapter).
Disconnect the connector [A].
Unscrew the mounting bolts [B] and remove the regula-
tor/rectifier [C].

Regulator/Rectifier Output Voltage Inspection

Check the battery condition (see Battery Condition).
Warm up the engine to obtain actual alternator operating
Remove the left side cover (see Left Side Cover Removal
in the Frame chapter).
Check that the ignition switch is turned off, and connect
the hand tester [A] as shown in the table.


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