Download  Print this page

Starter Clutch Inspection; Starter Relay Inspection; Brush Inspection; Brush Spring Inspection - Kawasaki EN500 Vulcan 500 LTD Service Manual

Hide thumbs


Table of Contents
Electric Starter System

Starter Clutch Inspection

Alternator Rotor (see Alternator Rotor/Starter Clutch Re-
Starter Chain Guide (see Starter Motor Removal)
Starter Motor Sprocket (see Starter Motor Removal)
Starter Chain (see Starter Clutch Sprocket Removal)
Install the alternator rotor with the starter clutch.
Turn the starter clutch sprocket [A] by hand. The starter
clutch sprocket should turn counterclockwise freely [B],
but should not turn [C] clockwise.
If the clutch does not operate as it should or if it makes
noise, disassemble the starter clutch, examine each part,
and replace any worm or damaged parts.

Starter Relay Inspection

Remove the left side cover (see Left Side Cover Removal
in the Frame chapter).
Remove the starter relay.
Connect a hand tester [A] and one 12 V battery [B] to the
starter relay [C] as shown.
If the relay does not work as specified, the relay is defec-
tive. Replace the relay.
Testing Relay
Meter range:
× 1 Ω
When battery is connected → 0 Ω
When battery is disconnected → ∞ Ω

Brush Inspection

Measure the length [A] of each brush.
If any is worn down to the service limit, replace the brush
plate assembly [B].
Starter Motor Brush Length
12.0 ∼ 12.5 mm (0.472 ∼ 0.492 in.)
Service Limit:
8.5 mm (0.335 in.)

Brush Spring Inspection

Check that the brush springs are in place and will snap
the brushes firmly into place.
If not, reinstall or replace the spring.


Table of Contents

   Also See for Kawasaki EN500 Vulcan 500 LTD

This manual is also suitable for:

Vulcan 500 ltd

Comments to this Manuals

Symbols: 0
Latest comments:
  • 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