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Fuel Tank Installation; Fuel Tap Removal; Fuel Tap Installation; Fuel Tank And Tap Cleaning - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Fuel Tank

Fuel Tank Installation

Read the WARNING in the Fuel Tank Removal section.
Check the rubber dampers [A] on the frame top-tube.
If the dampers are damaged or deteriorated, replace
Route the hoses and leads correctly (see Cable, Wire and
Hose Routing in the Appendix chapter).
Be sure the hoses are clamped to the fuel tap and fuel
tank to prevent leaks.

Fuel Tap Removal

Remove the fuel tank and drain it.
Remove the bolts [A] with nylon flat washers and take out
the fuel tap [B].

Fuel Tap Installation

Fuel tap installation is the reverse of removal. Note the
Be sure the O-ring is in good condition to prevent leaks.
Be sure to clamp the fuel hose to the tap to prevent leaks.
Be sure the nylon washers are in good condition to pre-
vent leaks.
Torque - Fuel Tap Mounting Bolts:
2.5 N·m ( 0.25 kgf·m, 22 in·lb)
(with white washer)
4.9 N·m ( 0.5 kgf·m, 43 in·lb)
(with black washer)
Do not use steel washers in place of the nylon washers,
because they will not seal the bolts properly and fuel will

Fuel Tank and Tap Cleaning

Remove the fuel tank and drain it.
Pour some high-flash point solvent into the fuel tank and
shake the tank to remove dirt and fuel deposits.
Clean the tank in a well-ventilated area, and take
care that there are no sparks or flame anywhere
near the working area; this includes any appliance
with a pilot light. Because of the danger of highly
flammable liquids, do not use gasoline or low flash
-point solvents to clean the tank.
Pour the solvent out of the tank.
Remove the fuel tap from the tank by taking out the bolts
with nylon washers.
Clean the fuel tap filter screens in a high-flash point sol-


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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