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Exhaust Smokes Excessively; Abnormal Drive Train Noise; Abnormal Frame Noise - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Troubleshooting Guide
Exhaust pipe leaking at cylinder head con-
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Primary chain worn
Camshaft chain tensioner trouble
Camshaft chain, sprocket, guide worn
Air suction valve damaged
Vacuum switch valve damaged
Alternator rotor loose
Balancer gear worn or chipped
Balancer shaft position maladjusted
Balancer bearing worn
Starter chain, sprocket, guide worn

Abnormal Drive Train Noise:

Clutch noise:
Clutch rubber damper weak or damaged
Clutch housing/friction plate clearance ex-
Clutch housing gear worn
Transmission noise:
Bearings worn
Transmission gears worn or chipped
Metal chips jammed in gear teeth
Engine oil insufficient
Drive line noise:
Drive chain adjusted improperly
Drive chain worn
Rear and/or engine sprocket worn
Chain lubrication insufficient
Rear wheel misaligned

Abnormal Frame Noise:

Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock absorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Drum brake noise:
Brake linings overworn or worn unevenly
Drum worn unevenly or scored
Brake springs weak or broken
Foreign matter in hub
Brake not properly adjusted
Other noise:
Bracket, nut, bolt, etc.
mounted or tightened
Oil Pressure Warning Light Goes On:

Exhaust Smokes Excessively:

Handling and/or Stability
not properly
Engine oil pump damaged
Engine oil screen clogged
Engine oil level too low
Engine oil viscosity too low
Camshaft bearing worn
Crankshaft bearings worn
Balancer bearings worn
Oil pressure switch damaged
Wiring faulty
Relief valve stuck open
O-ring at the oil passage in the crankcase
White smoke:
Piston oil ring worn
Cylinder worn
Valve oil seal damaged
Valve guide worn
Cylinder head gasket damaged
Engine oil level too high
Black smoke:
Air cleaner clogged
Main jet too large or fallen off
Choke plunger stuck open
Fuel level in carburetor float bowl too high
Brown smoke:
Main jet too small
Fuel level in carburetor float bowl too low
Air cleaner duct loose
Air cleaner O-ring damaged
Air cleaner poorly sealed or missing
Handlebar hard to turn:
Cable routing incorrect
Hose routing incorrect
Wiring routing incorrect
Steering stem locknut too tight
Steering stem bearing damaged
Steering stem bearing lubrication inade-
Steering stem bent
Tire air pressure too low
Handlebar shakes or excessively vibrates:
Tire worn
Swingarm pivot bearings worn
Rim warped, or not balanced
Wheel bearing worn
Handlebar clamp loose
Steering stem head bolt loose
Handlebar pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted


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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