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Filler Neck Inspection; Radiator Cap Inspection; Radiator Hose, Reserve Tank Hose Inspection; Radiator Hose, Pipe, Air Vent Hose, Reserve Tank Hose Installation - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Radiator, Radiator Fan

Filler Neck Inspection

Check the radiator filler neck for signs of damage.
Check the condition of the top [A] and bottom sealing
seats [B] in the filler neck. They must be smooth and
clean for the radiator cap to function properly.

Radiator Cap Inspection

Check the condition of the valve spring [C], and the top
[A] and bottom [B] valve seals of the radiator cap.
If any one of them shows visible damage, replace the cap
with a new one.
Install the cap [A] on a cooling system pressure tester [B].
Wet the cap sealing surfaces with water or coolant to
prevent pressure leaks.
Watching the pressure gauge, slowly pump the pressure
tester to build up the pressure. The relief valve must open
within the relief pressure range as shown below. The
gauge hand must remain at least 6 seconds between the
lowest relief pressure and the valve opened pressure.
Radiator Cap Relief Pressure
93 ∼ 123 kPa (0.95 ∼ 1.25 kgf/cm², 14 ∼ 18
If the cap cannot hold the specified pressure, or if it holds
too much pressure, replace it with a new one.

Radiator Hose, Reserve Tank Hose Inspection

In accordance with the Periodic Maintenance Chart, visu-
ally inspect the hoses for signs of deterioration. Squeeze
the hose. A hose should not be hard and brittle, nor
should it be soft or swollen.
Replace any damaged hose.
Radiator Hose, Pipe, Air Vent Hose, Reserve Tank
Hose Installation
Install the radiator hoses. Avoid sharp bending, kinking,
flattening, or twisting.
Tighten the hose clamps securely.
Torque - Radiator Hose Clamp Screws: 2.5 N·m (0.25 kgf·m,
22 in·lb)
Route the air vent hose, radiator hoses, pipes and reserve
tank hose (see Cable, Wire and Hose Routing in the Ap-
pendix chapter).


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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