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Cylinder Head Warp Inspection; Cylinder Head Cleaning - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Cylinder Head
Install a new cylinder head gasket with "UP" [A] marked
side positioning to the right.
The camshaft caps are machined with the cylinder head
so if a new cylinder head is installed, use the caps that
are supplied with the new head.
Tighten the 10 mm cylinder head bolts following the tight-
ening sequence. Tighten them first to about one half of
the specified torque.
Torque - Cylinder Head Bolts 10 mm: 51 N·m (5.2 kgf·m, 38
Cylinder Head Bolts 6 mm: 9.8 N·m (1.0 kgf·m, 87
Tighten the 6 mm cylinder bolts.
Install the camshafts, camshaft caps and top chain guide.
Install the head oil pipes.

Cylinder Head Warp Inspection

Clean the cylinder head (see Cylinder Head Cleaning).
Lay a straightedge [A] across the lower surface of the
head at several different points, and measure warp by
inserting a thickness gauge [B] between the straightedge
and the head.
If warp exceeds the service limit, repair the mating sur-
face. Replace the cylinder head if the mating surface is
badly damaged.
Cylinder Head Warp
Service Limit:

Cylinder Head Cleaning

Remove the cylinder head (see Cylinder Head Removal).
Remove the valves (see Valve Removal).
Wash the head with a high-flash point solvent.
Scrape [A] the carbon out of the combustion chamber and
exhaust port with a suitable tool.
0.05 mm (0.002 in.)


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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