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Kawasaki Manuals
Motorcycle
EN500 Vulcan 500 LTD
Service manual
Meter Instruments; Meter Instruments Removal; Meter Instruments Installation; Meter Unit Disassembly - Kawasaki EN500 Vulcan 500 LTD Service Manual
Motorcycle.
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Also See for EN500 Vulcan 500 LTD
Service manual
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338 pages
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Page
of
351
Go
Page 1
Page 2
Page 3
Page 4
Page 5 - Emission control information
Page 6
Page 7 - How to use this manual
Page 8
Page 9 - Table Of Contents
Page 10 - Before Servicing
Page 11
Page 12
Page 13 - Model Identification
Page 14 - General Specifications (EN500-C1 ~ C6F M...
Page 15
Page 16
Page 17 - General Specifications (EN500C7F Model ~...
Page 18
Page 19
Page 20 - Periodic Maintenance Chart
Page 21
Page 22
Page 23
Page 24 - Torque and Locking Agent
Page 25
Page 26
Page 27
Page 28
Page 29 - Unit Conversion Table
Page 30
Page 31 - FUEL SYSTEM
Page 32 - Exploded View
Page 33
Page 34 - Specifications
Page 35 - Special Tools
Page 36 - Throttle Grip and Cable
Page 37 - Throttle Cable Inspection
Page 38 - Carburetors
Page 39 - Synchronization Adjustment
Page 40 - Service Fuel Level Adjustment
Page 41 - Fuel System Cleanliness Inspection
Page 42 - Carburetor installation
Page 43
Page 44 - Carburetor Separation/Assembly
Page 45 - Carburetor Inspection
Page 46 - Coolant Filter Cleaning (AT, DE, FR, IT,...
Page 47 - Air Cleaner
Page 48 - Air Cleaner Element Cleaning and Inspect...
Page 49 - Fuel Tank
Page 50 - Fuel Tank Installation
Page 51 - Fuel Tap Inspection
Page 52 - Evaporative Emission Control System (Cal...
Page 53 - Separator Operation Test
Page 54
Page 55
Page 56 - Exploded View
Page 57 - Specifications
Page 58 - Special Tool and Sealant
Page 59 - Coolant
Page 60
Page 61 - Coolant Filling
Page 62 - Cooling System Pressure Testing
Page 63 - Water Pump
Page 64 - Water Pump Housing Disassembly
Page 65 - Pump Impeller Inspection
Page 66 - Radiator, Radiator Fan
Page 67 - Radiator Installation
Page 68 - Filler Neck Inspection
Page 69 - Thermostat
Page 70
Page 71 - Radiator Fan Switch, Water Temperature S...
Page 72
Page 73
Page 74 - Exploded View
Page 75
Page 76 - Specifications
Page 77
Page 78
Page 79 - Special Tools and Sealant
Page 80
Page 81 - Clean Air System (US, CH, AT, KR, C2 ~ C...
Page 82 - Vacuum Switch Valve Test
Page 83 - Cylinder Head Cover
Page 84 - Camshaft Chain Tensioner
Page 85 - Camshaft, Camshaft Chain
Page 86 - Camshaft and Sprocket Assembly
Page 87 - Camshaft, Camshaft Cap Wear Inspection
Page 88 - Rocker Shaft, Rocker Arm
Page 89 - Oil Pipe
Page 90 - Cylinder Head
Page 91 - Cylinder Head Removal
Page 92 - Cylinder Head Warp Inspection
Page 93
Page 94 - Valves
Page 95 - Valve Clearance Adjustment
Page 96 - Valve Guide Removal
Page 97 - Measuring Valve-to-Guide Clearance (Wobb...
Page 98
Page 99
Page 100
Page 101
Page 102 - Cylinder, Piston
Page 103 - Piston Installation
Page 104 - Piston Ring, Piston Ring Groove Wear Ins...
Page 105 - Piston Diameter Measurement
Page 106 - Carburetor Holder
Page 107 - Exhaust Pipe, Muffler
Page 108 - Exhaust Pipe, Muffler Installation
Page 109
Page 110 - Exploded View
Page 111
Page 112 - Specifications
Page 113 - Special Tool and Sealant
Page 114 - Clutch Lever and Cable
Page 115 - Clutch Lever Installation
Page 116 - Right Engine Cover
Page 117 - Clutch Release Installation
Page 118 - Clutch Removal
Page 119 - Clutch Plate Wear, Damage Inspection
Page 120 - Clutch Spring Free Length Measurement
Page 121
Page 122 - Exploded View
Page 123
Page 124 - Engine Oil Flow Chart
Page 125 - Specifications
Page 126 - Special Tools and Sealant
Page 127 - Engine Oil and Oil Filter
Page 128 - Engine Oil Change
Page 129 - Oil Filter Change
Page 130 - Oil Pan and Relief Valve
Page 131 - Relief Valve Inspection
Page 132 - Oil Pump
Page 133 - Oil Pump Installation
Page 134 - Oil Screen Cleaning and Inspection
Page 135 - Oil Pressure Measurement
Page 136
Page 137
Page 138 - Exploded View
Page 139 - Special Tool
Page 140 - Engine Removal/Installation
Page 141 - Engine Installation
Page 142
Page 143
Page 144 - Exploded View
Page 145
Page 146 - Specifications
Page 147
Page 148
Page 149 - Special Tools and Sealant
Page 150 - Crankcase Splitting
Page 151 - Crankcase Splitting
Page 152
Page 153 - Clutch Housing/Primary Chain
Page 154 - Primary Chain Guide Wear
Page 155 - Crankshaft/Connecting Rods
Page 156 - Crankshaft/Connecting Rod Cleaning
Page 157 - Connecting Rod Big End Side Clearance In...
Page 158
Page 159 - Crankshaft Runout Inspection
Page 160
Page 161 - Crankshaft Side Clearance Inspection
Page 162 - Balancer
Page 163
Page 164
Page 165 - Transmission
Page 166 - External Shift Mechanism Inspection
Page 167 - Transmission Shaft Installation
Page 168 - Drive Shaft Assembly
Page 169 - Output Shaft Assembly
Page 170 - Shift Drum and Fork Removal
Page 171 - Shift Drum and Fork Installation
Page 172 - Shift Drum Disassembly
Page 173 - Ball and Needle Bearing Wear Inspection
Page 174
Page 175
Page 176 - Exploded View
Page 177 - Specifications
Page 178 - Special Tools
Page 179 - Wheels (Rims)
Page 180 - Rear Wheel Installation
Page 181 - Wheel Inspection
Page 182 - Rim Inspection
Page 183 - Balance Adjustment
Page 184 - Tires
Page 185 - Tire Installation
Page 186
Page 187 - Hub Bearing
Page 188 - Hub Bearing Inspection
Page 189 - Speedometer Gear
Page 190
Page 191
Page 192 - Exploded View
Page 193 - Specifications
Page 194 - Special Tools
Page 195 - Drive Chain
Page 196 - Wheel Alignment Inspection/Adjustment
Page 197 - Drive Chain Lubrication
Page 198 - Drive Chain Removal
Page 199
Page 200
Page 201
Page 202 - Sprocket, Coupling
Page 203 - Rear Sprocket Removal
Page 204 - Coupling Bearing Removal
Page 205 - Coupling Bearing Inspection and Lubricat...
Page 206
Page 207
Page 208 - Exploded View
Page 209
Page 210 - Specifications
Page 211 - Special Tool
Page 212 - Caliper
Page 213 - Caliper Assembly
Page 214 - Fluid Seal Damage Inspection
Page 215 - Brake Pads
Page 216 - Master Cylinder
Page 217 - Master Cylinder Assembly
Page 218 - Brake Disc
Page 219 - Brake Fluid
Page 220 - Bleeding the Brake Line
Page 221
Page 222 - Brake Hose
Page 223 - Brake Pedal and Cable
Page 224 - Brake Pedal Removal
Page 225 - Brake Cable Lubrication
Page 226 - Brake Panel and Drum
Page 227 - Brake Panel Disassembly
Page 228 - Brake Shoe Lining Wear Inspection
Page 229 - Brake Drum Wear Inspection
Page 230
Page 231
Page 232 - Exploded View
Page 233
Page 234 - Specifications
Page 235 - Special Tools
Page 236 - Front Fork
Page 237
Page 238 - Front Fork Disassembly
Page 239 - Front Fork Assembly
Page 240 - Inner Tube Inspection
Page 241 - Dust Seal Inspection
Page 242 - Rear Shock Absorber
Page 243 - Rear Shock Absorber Installation
Page 244 - Swingarm
Page 245
Page 246 - Exploded View
Page 247 - Special Tools
Page 248 - Steering Inspection
Page 249
Page 250 - Steering Stem
Page 251 - Steering Stem, Stem Bearing Installation
Page 252 - Steering Stem Bearing Inspection and Lub...
Page 253 - Handlebar
Page 254
Page 255
Page 256 - Exploded View
Page 257
Page 258 - Seat
Page 259 - Side Covers
Page 260 - Fender
Page 261 - Storage Case
Page 262 - Battery Case
Page 263
Page 264
Page 265 - Parts Location
Page 266 - Exploded View
Page 267 - Electrical system
Page 268
Page 269
Page 270 - Specifications
Page 271 - Special Tools and Sealant
Page 272 - Wiring Diagram (United States and Canada...
Page 273
Page 274 - Wiring Diagram (Other than United States...
Page 275
Page 276 - Wiring Diagram (United States and Canada...
Page 277
Page 278 - Wiring Diagram (Other than United States...
Page 279
Page 280 - Wiring Diagram (United States and Canada...
Page 281
Page 282 - Wiring Diagram (Other than United States...
Page 283
Page 284 - Precautions
Page 285
Page 286 - Electrical Wiring
Page 287 - Battery
Page 288 - Battery Initial Charging
Page 289
Page 290 - Battery Ordinary Charging
Page 291 - Battery Test Charging
Page 292
Page 293 - Charging System
Page 294 - Alternator Rotor/Starter Clutch Installa...
Page 295 - Alternator Stator Removal
Page 296
Page 297 - Alternator Inspection
Page 298 - Rectifier Inspection
Page 299
Page 300 - Ignition System
Page 301 - Ignition Coil Removal/Installation
Page 302 - Ignition Timing Inspection
Page 303 - Spark Plug Removal/Installation
Page 304 - IC Igniter Installation
Page 305 - Diodes Inspection
Page 306
Page 307
Page 308 - Electric Starter System
Page 309 - Starter Clutch Sprocket Removal
Page 310 - Starter Motor Assembly
Page 311 - Starter Clutch Inspection
Page 312 - Commutator Cleaning and Inspection
Page 313 - Brush Plate Inspection
Page 314 - Electric Starter Circuit
Page 315 - Lighting System
Page 316 - Headlight Unit/Housing Removal
Page 317 - Turn Signal Light Bulb Replacement
Page 318
Page 319
Page 320
Page 321 - Radiator Fan System
Page 322
Page 323 - Meter Instruments
Page 324 - Switches and Sensors
Page 325 - Radiator Fan Switch Inspection
Page 326 - Water Temperature Switch Inspection
Page 327 - Junction Box
Page 328 - Diode Circuit Inspection
Page 329
Page 330 - Fuses
Page 331
Page 332 - Troubleshooting Guide
Page 333
Page 334 - Gear shifting faulty
Page 335 - Exhaust smokes excessively
Page 336 - Battery trouble
Page 337 - General Lubrication
Page 338 - Nut, Bolt, and Fastener Tightness
Page 339 - Cable, Wire, and Hose Routing
Page 340
Page 341
Page 342
Page 343
Page 344
Page 345
Page 346
Page 347
Page 348
Page 349
Page 350
Page 351
/
351
Contents
Table of contents
Troubleshooting
Bookmarks
Advertisement
Meter Instruments
Meter Instruments Removal
•
Remove the bolt [A], and separate the meter instruments
[B] from the fuel tank.
•
Remove:
Connectors [A]
Speedometer Cable [B]
Place the meter so that the face is up. If a meter is
left upside down or sideways for any length of time,
it will malfunction.
Meter Instruments Installation
•
Insert the tongue [A] of the meter bracket into the damper
slit [B] on the fuel tank.
Meter Unit Disassembly
•
Remove:
Meter Instruments
Screw and Knob [A]
Screws [B]
Speedometer [C]
Bulb Replacement
•
To remove the wedge-base type bulbs [A] (indicator and
illumination), pull out the bulb sockets [B] and pull the
bulbs out of the sockets.
Do not turn the bulb. Pull the bulb out to prevent
damage to the bulb.
Do not use bulbs rated for greater wattage than the
specified value.
CAUTION
CAUTION
ELECTRICAL SYSTEM 15-61
Table of
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Quick Links:
Engine Oil/Filter
Electric Starter Circuit
Front Fork
Fuel Tank
Carburetor Disassembly/Assembly
Fuel System Cleanliness Inspection
Carburetor Removal
Spring Preload Adjustment
Rear Shock Absorber Removal
Ignition System
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Chapters
General Information 1
9
Fuel System
31
Cooling System
55
Engine Top End
73
Clutch
109
Engine Lubrication System
121
Table Of Contents
137
Crankshaft/transmission
143
Wheels/tires
175
Final Drive
191
Brakes
207
Suspension
231
Steering
245
Frame
255
Electrical System
263
Table of Contents
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Kawasaki EN500 Service Manual
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This manual is also suitable for:
Vulcan 500 ltd
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Latest comments:
Ricardo Paluan
Apr 27, 2016 01:22:
Adquiri recentemente uma moto vulcan 500 ano 1995. Tenho o 37 anos e iniciante no mundo motociclista. Entretanto, em razão só tempo e idade da moto, não tenho o manual do proprietário, sendo este indispens
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