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Starter Clutch Sprocket Removal; Starter Clutch Sprocket Installation; Starter Motor Disassembly - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Electric Starter System

Starter Clutch Sprocket Removal

Remove:
Alternator cover (see Alternator Rotor/Starter Clutch Re-
moval)
Alternator rotor with Starter Clutch (see Alternator Ro-
tor/Starter Clutch Removal)
Remove the woodruff key [A] and washer [B].
Remove the starter chain guide with the guide stay.
Remove the starter clutch sprocket [C], starter motor
sprocket and starter chain as a set.
In case that the starter motor has been removed, do the
following:
Remove the starter motor sprocket.
Remove the alternator rotor with the starter clutch, starter
clutch sprocket and starter chain as a set.

Starter Clutch Sprocket Installation

Apply a thin coat of molybdenum disulfide grease to the
frictional surface between the crankshaft and the starter
clutch sprocket.
If the starter motor has been removed, install it first.
Install the starter clutch sprocket, starter motor sprocket
and starter chain as a set.
Install the alternator rotor with the starter clutch and alter-
nator cover.

Starter Motor Disassembly

Unscrew the starter motor through bolts [A] and pull off the
gear cover [B] and the end cover [C] with the end bracket
[F].
Pull the armature [D] out of the yoke housing [E].
Remove the terminal nut [A], and take the brush plate [B]
off the end cover [C].
ELECTRICAL SYSTEM 15-47

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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