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Spark Plug Removal/installation; Spark Plug Cleaning, Inspection; Spark Plug Gap Inspection; Ic Igniter Removal - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Table of Contents
Ignition System

Spark Plug Removal/Installation

Remove the fuel tank (see Fuel Tank Removal in the Fuel
System chapter).
Carefully pull the spark plug cap from the spark plug and
unscrew the spark plug.
Using the 18 mm plug wrench [A].
Tighten the spark plug.
Torque - Spark Plug: 14 N·m (1.4 kgf·m, 10 ft·lb)
Fit the plug cap securely.

Spark Plug Cleaning, Inspection

Remove the spark plug.
Clean the spark plug, preferably in a sandblasting device,
and then clean off any abrasive particles. The plug may
also be cleaned using a high-flash point solvent and a wire
brush or other suitable tool.
If the spark plug center electrode [B] and/or side elec-
trode [D] are corroded or damaged, or if the insulator [A]
is cracked, replace the plug.
Use the standard spark or its equivalent.
Special Tool - Spark Plug Wrench: 57001-1024

Spark Plug Gap Inspection

Remove the spark plug.
Measure the gap [C] with a wire-type thickness gauge.
Spark Plug Gap
0.6 ∼ 0.7 mm (0.024 ∼ 0.028 in.)
Special Tool - Spark Plug Wrench: 57001-1024
If the gap is incorrect, carefully bend the side electrode
with a suitable tool to obtain the correct gap.

IC Igniter Removal

When inspecting the IC igniter observe the follow-
ing to avoid damage to the IC Igniter.
Do not disconnect the IC igniter with the ignition
switch on. This may damage the IC igniter.
Do not disconnect the battery leads while the en-
gine is running. This may damage the IC igniter.
Unscrew the bolt [A] from the IC igniter bracket.
Pull out the IC igniter [B].
Disconnect the IC igniter lead connectors.


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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