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Valve Clearance Adjustment; Valve Removal; Valve Installation - Kawasaki EN500 Vulcan 500 LTD Service Manual

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Measure the clearance of each valve by inserting a thick-
ness gauge [A] between the adjusting screw [B] and the
valve stem.
Valve Clearance (when cold)
0.13 ∼ 0.18 mm (0.0051 ∼ 0.0070 in.)
0.18 ∼ 0.23 mm (0.0070 ∼ 0.0091 in.)

Valve Clearance Adjustment

If the valve clearance is incorrect, loosen the locknut [A]
and turn the adjusting screw [B] until the correct clearance
is obtained.
Tighten the locknut.
Torque - Valve Adjuster Locknuts: 25 N·m (2.5 kgf·m, 18
Install the two caps on the alternator cover.

Valve Removal

Remove the cylinder head (see Cylinder Head Removal).
Use a valve spring compressor assembly to press down
the valve spring retainer, and remove the split keepers.
Special Tools - Valve Spring Compressor Assembly [A]:
Valve Spring Compressor Adapter, 22 [B]:

Valve Installation

Check to see that the valve [A] moves smoothly up and
down in the guide.
Check to see that the valve seats properly in the valve
seat. If it does not, repair the valve seat.
Replace the oil seal [B] with a new one.
Apply a thin coat of molybdenum disulfide grease to the
valve stem before valve installation.
Be sure to install the inner [C] and outer [D] spring seats
under the inner [E] and outer [F] springs.
Install the springs so that the closed coil [G] end is facing
toward the valve seat (downwards).
Install the spring retainer [H], press it down with the valve
spring compressor assembly, and fit the split keeper [I]
into place.
Special Tools - Valve Spring Compressor Assembly: 57001
Valve Spring Compressor Adapter,
Install the other removed parts.


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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