Kawasaki EN500 Vulcan 500 LTD Manuals

Manuals and User Guides for Kawasaki EN500 Vulcan 500 LTD. We have 2 Kawasaki EN500 Vulcan 500 LTD manuals available for free PDF download: Service Manual

Kawasaki EN500 Vulcan 500 LTD Service Manual (351 pages)

Motorcycle

Brand: Kawasaki | Category: Motorcycle | Size: 8.4 MB

Emission Control Information 5

How To Use This Manual 7

Table Of Contents 9

Before Servicing 10

Model Identification 13

General Specifications (EN500-C1 ~ C6F Models) 14

General Specifications (EN500C7F Model ~) 17

Periodic Maintenance Chart 20

Torque And Locking Agent 24

Unit Conversion Table 29

FUEL SYSTEM 31

Exploded View 32

Specifications 34

Special Tools 35

Throttle Grip And Cable 36

Throttle Grip Free Play Inspection 36

Throttle Cable Adjustment 36

Throttle Cable Inspection 37

Throttle Cable Lubrication 37

Carburetors 38

Idle Speed Inspection 38

Idle Speed Adjustment 38

High Altitude Performance Adjustment (United States Model) 38

Synchronization Adjustment 39

Service Fuel Level Inspection 39

Service Fuel Level Adjustment 40

Fuel System Cleanliness Inspection 41

Carburetor Removal 41

Carburetor Installation 42

Carburetor Disassembly/Assembly 42

Carburetor Separation/Assembly 44

Carburetor Cleaning 44

Carburetor Inspection 45

Coolant Filter Cleaning (AT, DE, FR, IT, NL, CH, GB, KR, Models) 46

Air Cleaner 47

Air Cleaner Housing Removal 47

Air Cleaner Housing Installation 47

Air Cleaner Element Removal/Installation 47

Air Cleaner Element Cleaning And Inspection 48

Oil Draining 48

Fuel Tank 49

Fuel Tank Removal 49

Fuel Tank Installation 50

Fuel Tap Removal 50

Fuel Tap Installation 50

Fuel Tank And Tap Cleaning 50

Fuel Tap Inspection 51

Fuel Tank And Cap Inspection 51

Evaporative Emission Control System (California Model Only) 52

Parts Removal/Installation 52

Hose Inspection 52

Separator Inspection 52

Separator Operation Test 53

Canister Inspection 53

Exploded View 56

Specifications 57

Cooling System 57

Special Tool And Sealant 58

Coolant 59

Coolant Deterioration 59

Coolant Level Inspection 59

Coolant Draining 59

Coolant Filling 61

Visual Leak Inspection 61

Cooling System Pressure Testing 62

Flushing 62

Coolant Filter Cleaning 62

Water Pump 63

Water Pump Removal 63

Water Pump Installation 63

Water Pump Housing Disassembly 64

Water Pump Housing Assembly 64

Impeller Assembly 64

Pump Impeller Inspection 65

Mechanical Seal Inspection 65

Radiator, Radiator Fan 66

Radiator Fan Removal 66

Radiator Fan Installation 66

Radiator Removal 66

Radiator Installation 67

Radiator Inspection 67

Filler Neck Inspection 68

Radiator Cap Inspection 68

Radiator Hose, Reserve Tank Hose Inspection 68

Radiator Hose, Pipe, Air Vent Hose, Reserve Tank Hose Installation 68

Thermostat 69

Thermostat Removal 69

Thermostat Installation 69

Thermostat Inspection 69

Radiator Fan Switch, Water Temperature Switch 71

Radiator Fan Switch Removal 71

Water Temperature Switch Removal 71

Radiator Fan Switch, Water Temperature Switch Installation 71

Exploded View 74

Engine Top End 74

Specifications 76

Special Tools And Sealant 79

Clean Air System (US, CH, AT, KR, C2 ~ CA, DE & C6 ~ EUR, FR) 81

Air Suction Valve Installation 81

Vacuum Switch Valve Installation 81

Air Suction Valve Inspection 81

Vacuum Switch Valve Test 82

Cylinder Head Cover 83

Cylinder Head Cover Removal 83

Cylinder Head Cover Installation 83

Camshaft Chain Tensioner 84

Camshaft Chain Tensioner Removal 84

Camshaft Chain Tensioner Installation 84

Camshaft, Camshaft Chain 85

Camshaft Removal 85

Camshaft Installation 85

Camshaft And Sprocket Assembly 86

Camshaft, Camshaft Cap Wear Inspection 87

Camshaft Chain Guide Wear Inspection 87

Rocker Shaft, Rocker Arm 88

Rocker Shaft, Rocker Arm Removal 88

Rocker Shaft, Rocker Arm Installation 88

Oil Pipe 89

Cylinder Head Oil Pipe Removal 89

Cylinder Head Oil Pipe Installation 89

Main Oil Pipe Removal 89

Cylinder Head 90

Compression Measurement 90

Cylinder Head Removal 91

Cylinder Head Installation 91

Cylinder Head Warp Inspection 92

Cylinder Head Cleaning 92

Valves 94

Valve Clearance Inspection 94

Valve Clearance Adjustment 95

Valve Removal 95

Valve Installation 95

Valve Guide Removal 96

Valve Guide Installation 96

Valve Seat Inspection 96

Measuring Valve-to-Guide Clearance (Wobble Method) Inspection 97

Valve Seat Repair 97

Cylinder, Piston 102

Cylinder Removal 102

Cylinder Installation 102

Piston Removal 102

Piston Installation 103

Piston Ring, Piston Ring Groove Wear Inspection 104

Piston Ring End Gap Inspection 104

Cylinder Inside Diameter Measurement 104

Piston Diameter Measurement 105

Boring, Honing 105

Carburetor Holder 106

Carburetor Holder Installation 106

Exhaust Pipe, Muffler 107

Exhaust Pipe, Muffler Removal 107

Exhaust Pipe, Muffler Installation 108

Exploded View 110

Specifications 112

Special Tool And Sealant 113

Clutch Lever And Cable 114

Clutch Lever Free Play Inspection 114

Clutch Lever Free Play Adjustment 114

Clutch Lever Installation 115

Cable Lubrication 115

Right Engine Cover 116

Clutch Cover Removal 116

Clutch Cover Installation 116

Clutch Release Removal 116

Clutch Release Installation 117

Clutch 117

Clutch Removal 118

Clutch Installation 118

Clutch Plate Wear, Damage Inspection 119

Clutch Plate Warp Inspection 119

Clutch Spring Free Length Measurement 120

Clutch Housing Finger Inspection 120

Clutch Hub Spline Inspection 120

Exploded View 122

Engine Lubrication System 122

Engine Oil Flow Chart 124

Specifications 125

Special Tools And Sealant 126

Engine Oil And Oil Filter 127

Engine Oil Level Inspection 127

Engine Oil Change 128

Oil Filter Change 129

Oil Pan And Relief Valve 130

Oil Pan Removal 130

Oil Pan Installation 130

Relief Valve Removal 130

Relief Valve Inspection 131

Oil Pump 132

Oil Pump Removal 132

Oil Pump Installation 133

Oil Pump Disassembly 133

Oil Pump Assembly 133

Oil Screen Cleaning And Inspection 134

Oil Pressure Measurement 135

Exploded View 138

Special Tool 139

Engine Removal/Installation 140

Engine Removal 140

Engine Installation 141

Specifications 146

Special Tools And Sealant 149

Crankcase Splitting 150

Crankcase Assembly 151

Clutch Housing/Primary Chain 153

Clutch Housing/Primary Chain Removal 153

Clutch Housing/Primary Chain Installation 153

Primary Chain Guide Wear 154

Crankshaft/Connecting Rods 155

Crankshaft Removal 155

Crankshaft Installation 155

Connecting Rod Removal 155

Crankshaft/Connecting Rod Cleaning 156

Connecting Rod Bend/Twist Inspection 156

Connecting Rod Big End Side Clearance Inspection 157

Connecting Rod Big End Bearing Insert/Crankpin Clearance Inspection 157

Crankshaft Runout Inspection 159

Crankshaft Main Bearing Insert/Journal Clearance Inspection 159

Crankshaft Side Clearance Inspection 161

Balancer 162

Balancer Removal 162

Balancer Installation 162

Balancer Shaft Bearing Insert/Journal Clearance Inspection 162

Transmission 165

External Shift Mechanism Removal 165

External Shift Mechanism Installation 165

External Shift Mechanism Inspection 166

Transmission Shaft Removal 166

Transmission Shaft Installation 167

Transmission Shaft Disassembly 167

Drive Shaft Assembly 168

Output Shaft Assembly 169

Shift Drum And Fork Removal 170

Shift Drum And Fork Installation 171

Shift Drum Disassembly 172

Shift Drum Assembly 172

Ball And Needle Bearing Wear Inspection 173

Shift Pedal, Shift Pedal Linkage Removal 173

Shift Pedal, Shift Pedal Linkage Installation 173

Exploded View 176

Specifications 177

Special Tools 178

Wheels (Rims) 179

Front Wheel Removal 179

Front Wheel Installation 179

Rear Wheel Removal 179

Rear Wheel Installation 180

Wheel Inspection 181

Spoke Inspection 181

Rim Inspection 182

Axle Inspection 182

Balance Inspection 182

Balance Adjustment 183

Tires 184

Air Pressure Inspection/Adjustment 184

Tire Inspection 184

Tire Removal 184

Tire Installation 185

Hub Bearing 187

Hub Bearing Removal 187

Hub Bearing Installation 187

Hub Bearing Inspection 188

Speedometer Gear 189

Disassembly And Assembly 189

Lubrication 189

Exploded View 192

Final Drive 192

Specifications 193

Special Tools 194

Drive Chain 195

Drive Chain Slack Inspection 195

Drive Chain Slack Adjustment 195

Wheel Alignment Inspection/Adjustment 196

Drive Chain Wear Inspection 196

Drive Chain Lubrication 197

Drive Chain Removal 198

Drive Chain Installation 198

Drive Chain Replacement (EN500-C9 ~) 198

Sprocket, Coupling 202

Engine Sprocket Removal 202

Engine Sprocket Installation 202

Rear Sprocket Removal 203

Rear Sprocket Installation 203

Sprocket Wear Inspection 203

Rear Sprocket Warp Inspection 203

Coupling Bearing Removal 204

Coupling Bearing Installation 204

Coupling Installation 204

Coupling Bearing Inspection And Lubrication 205

Exploded View 208

Specifications 210

Special Tool 211

Caliper 212

Caliper Removal 212

Caliper Installation 212

Caliper Disassembly 212

Caliper Assembly 213

Fluid Seal Damage Inspection 214

Dust Seal And Cover Damage Inspection 214

Piston Cylinder Damage Inspection 214

Caliper Holder Shaft Wear Inspection 214

Brake Pads 215

Brake Pad Removal 215

Brake Pad Installation 215

Brake Pad Lining Wear Inspection 215

Master Cylinder 216

Master Cylinder Removal 216

Master Cylinder Installation 216

Master Cylinder Disassembly 216

Master Cylinder Assembly 217

Master Cylinder Inspection (Visual Inspection) 217

Brake Disc 218

Brake Disc Removal 218

Brake Disc Installation 218

Brake Disc Wear Inspection 218

Brake Fluid 219

Brake Fluid Level Inspection 219

Brake Fluid Change 219

Bleeding The Brake Line 220

Brake Hose 222

Brake Hose Inspection 222

Brake Hose Replacement 222

Brake Pedal And Cable 223

Brake Pedal Position Inspection 223

Brake Pedal Position Adjustment 223

Brake Pedal Free Play Inspection 223

Brake Pedal Removal 224

Brake Pedal Installation 224

Brake Cable Lubrication 225

Brake Panel And Drum 226

Cam Lever Angle Inspection 226

Cam Lever Angle Adjustment 226

Brake Panel Removal 226

Brake Panel Disassembly 227

Brake Panel Assembly 227

Brake Shoe Lining Wear Inspection 228

Brake Shoe Spring Inspection 228

Brake Camshaft And Camshaft Hole Wear Inspection 228

Brake Drum Wear Inspection 229

Brake Lubrication 229

Exploded View 232

Specifications 234

Special Tools 235

Front Fork 236

Front Fork Removal (each Fork Leg) 236

Front Fork Installation 236

Fork Oil Change 236

Front Fork Disassembly 238

Front Fork Assembly 239

Inner Tube Inspection 240

Dust Seal Inspection 241

Spring Tension Inspection 241

Rear Shock Absorber 242

Spring Preload Adjustment 242

Rear Shock Absorber Removal 242

Rear Shock Absorber Installation 243

Rear Shock Absorber Wear Inspection 243

Bushing Wear Inspection 243

Swingarm 244

Swingarm Removal 244

Swingarm Installation 244

Swingarm Disassembly/Assembly 244

Exploded View 246

Special Tools 247

Steering 247

Steering Inspection 248

Steering Adjustment 248

Steering Stem 250

Steering Stem, Stem Bearing Removal 250

Steering Stem, Stem Bearing Installation 251

Steering Stem Bearing Inspection And Lubrication 252

Grease Seal Deterioration, Damage Inspection 252

Steering Stem Warp Inspection 252

Handlebar 253

Handlebar Removal 253

Handlebar Installation 253

Seat 258

Seat Removal/Installation 258

Side Covers 259

Right Side Cover Removal 259

Right Side Cover Installation 259

Left Side Cover Removal 259

Fender 260

Front Fender Removal 260

Front Fender Installation 260

Rear Fender Removal 260

Storage Case 261

Storage Case Removal 261

Storage Case Installation 261

Battery Case 262

Parts Location 265

Exploded View 266

Electrical System 267

Specifications 270

Special Tools And Sealant 271

Wiring Diagram (United States And Canada) EN500-C1 ~ C4 Model 272

Wiring Diagram (Other Than United States And Canada) EN500-C1 ~ C3 Model 274

Wiring Diagram (United States And Canada) EN500-C5 Model 276

Wiring Diagram (Other Than United States And Canada) EN500-C4 ~ C7 Model 278

Wiring Diagram (United States And Canada) EN500-C6 280

Wiring Diagram (Other Than United States And Canada) EN500-C8 282

Precautions 284

Electrical Wiring 286

Wiring Inspection 286

Battery 287

Electrolyte Level Inspection 287

Battery Condition 287

Battery Initial Charging 288

Battery Ordinary Charging 290

Battery Test Charging 291

Charging System 293

Alternator Rotor/Starter Clutch Removal 293

Alternator Rotor/Starter Clutch Installation 294

Alternator Stator Removal 295

Alternator Stator Installation 295

Regulator/Rectifier Removal 295

Regulator/Rectifier Output Voltage Inspection 295

Alternator Inspection 297

Rectifier Inspection 298

Regulator Inspection 298

Ignition System 300

Safety Instructions 300

Crankshaft Sensor Removal 300

Crankshaft Sensor Installation 300

Ignition Coil Removal/Installation 301

Ignition Coil Inspection 301

Ignition Timing Inspection 302

Spark Plug Removal/Installation 303

Spark Plug Cleaning, Inspection 303

Spark Plug Gap Inspection 303

IC Igniter Removal 303

IC Igniter Installation 304

IC Igniter Inspection 304

Diodes Inspection 305

Electric Starter System 308

Starter Motor Removal 308

Starter Motor Installation 308

Starter Clutch Sprocket Removal 309

Starter Clutch Sprocket Installation 309

Starter Motor Disassembly 309

Starter Motor Assembly 310

Starter Chain Guide Wear Inspection 310

Starter Clutch Inspection 311

Starter Relay Inspection 311

Brush Inspection 311

Brush Spring Inspection 311

Commutator Cleaning And Inspection 312

Armature Inspection 312

Brush Plate Inspection 313

Electric Starter Circuit 314

Lighting System 315

Headlight Beam Horizontal Adjustment 315

Headlight Beam Vertical Adjustment 315

Headlight Bulb Replacement 315

Headlight Unit/Housing Removal 316

Headlight Unit Installation 316

Tail/Brake Light Bulb Replacement 316

Tail/Brake Light Lens Removal/Installation 316

Turn Signal Light Bulb Replacement 317

Turn Signal Relay Inspection 317

Radiator Fan System 321

Radiator Fan System Circuit Inspection 321

Radiator Fan Motor Inspection 321

Meter Instruments 323

Meter Instruments Removal 323

Meter Instruments Installation 323

Meter Unit Disassembly 323

Switches And Sensors 324

Front Brake Light Timing Inspection 324

Rear Brake Light Timing Inspection 324

Rear Brake Light Timing Adjustment 324

Radiator Fan Switch Inspection 325

Water Temperature Switch Inspection 326

Junction Box 327

Junction Box Fuse Circuit Inspection 327

Starter Circuit/Headlight Relay Inspection 327

Diode Circuit Inspection 328

Fuses 330

Ampere Fuse Removal 330

Junction Box Fuse Removal 330

Fuse Installation 330

Troubleshooting Guide 332

Gear Shifting Faulty 334

Abnormal Engine Noise 334

Over Cooling 334

Clutch Operation Faulty 334

Exhaust Smokes Excessively 335

Abnormal Drive Train Noise 335

Abnormal Frame Noise 335

Battery Trouble 336

General Lubrication 337

Lubrication 337

Nut, Bolt, And Fastener Tightness 338

Tightness Inspection 338

Cable, Wire, And Hose Routing 339

Kawasaki EN500 Vulcan 500 LTD Service Manual (338 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 28.97 MB

Quick Reference Guide 2

List Of Abbreviations 4

Emission Control Information 5

Tampering With Noise Control System Prohibited 6

General Information 8

Before Servicing 9

Two-Color Electrical 11

Model Identification 12

General Specifications 13

Periodic Maintenance Chart 16

Torque And Locking Agent 20

General Fasteners 23

Unit Conversion Table 24

Fuel System 25

Fuel System Exploded View 26

Fuel System Specifications 28

Fuel System Special Tools 29

Fuel Level Gauge 29

Pilot Screw Adjuster 29

Vacuum Gauge 29

Throttle Grip Free Play Inspection 30

Throttle Cable Adjustment 30

Throttle Cable Inspection 31

Throttle Cable Lubrication 31

Carburetors 32

Idle Speed Inspection 32

Idle Speed Adjustment 32

High Altitude Performance Adjustment (United States Model) 32

Synchronization Adjustment 33

Service Fuel Level Inspection 33

Service Fuel Level Adjustment 34

Fuel System Cleanliness Inspection 35

Carburetor Removal 35

Carburetor Installation 36

Carburetor Disassembly/Assembly 36

Carburetor Separation/Assembly 38

Carburetor Cleaning 38

Carburetor Inspection 39

Coolant Filter Cleaning 40

Air Cleaner 41

Housing Removal 41

Housing Installation 41

Air Cleaner Element Removal/Installation 41

Air Cleaner Element Cleaning And Inspection 42

Oil Draining 42

Fuel Tank Removal 43

Fuel Tank Installation 44

Fuel Tap Removal 44

Fuel Tap Installation 44

Fuel Tank And Tap Cleaning 44

Fuel Tap Inspection 45

Fuel Tank And Cap Inspection 45

Evaporative Emission Control System 46

Parts Removal/Installation 46

Hose Inspection 46

Separator Inspection 46

Separator Operation Test 47

Canister Inspection 47

Cooling System 48

Cooling System Exploded View 49

Cooling System Specifications 50

Cooling System Special Tool And Sealant 51

Bearing Driver Set 51

Kawasaki Bond (Silicone Sealant) 51

Coolant Deterioration 52

Coolant Level Inspection 52

Coolant Draining 52

Coolant Filling 54

Visual Leak Inspection 54

Cooling System Pressure Testing 55

Flushing 55

Water Pump Removal 56

Water Pump Installation 56

Water Pump Housing Disassembly 57

Water Pump Housing Assembly 57

Impeller Assembly 57

Water Pump Impeller Inspection 58

Mechanical Seal Inspection 58

Radiator Fan Removal 59

Radiator Fan Installation 59

Radiator Removal 59

Radiator Installation 60

Radiator Inspection 60

Filler Neck Inspection 61

Radiator Cap Inspection 61

Radiator Hose, Reservoir Tank Hose Inspection 61

Radiator Hose, Pipe, Air Vent Hose, Reservoir Tank Hose Installation 61

Thermostat Removal 62

Thermostat Installation 62

Thermostat Inspection 62

Radiator Fan Switch Removal 64

Water Temperature Sensor Removal 64

Radiator Fan Switch, Water Temperature Sensor Installation 64

Radiator Fan Switch, Water Temperature Sensor Inspection 64

Engine Top End 65

Engine Top End Exploded View 66

Engine Top End Specifications 68

Engine Top End Special Tools And Sealant 71

Engine Top End Clean Air System 73

Air Suction Valve Installation 73

Vacuum Switch Valve Installation 73

Air Suction Valve Inspection 73

Vacuum Switch Valve Test 74

Clean Air System Hose Inspection 74

Cylinder Head Cover Removal 75

Cylinder Head Cover Installation 75

Camshaft Chain Tensioner Removal 76

Camshaft Chain Tensioner Installation 76

Camshaft Removal 77

Camshaft Installation 77

Camshaft And Sprocket Assembly 78

Camshaft, Camshaft Cap Wear 79

Camshaft Chain Guide Wear 79

Rocker Shaft, Rocker Arm Removal 80

Rocker Shaft, Rocker Arm Installation 80

Cylinder Head Oil Pipe Removal 81

Cylinder Head Oil Pipe Installation 81

Main Oil Pipe Removal 81

Main Oil Pipe Installation 81

Cylinder Head 82

Compression Measurement 82

Cylinder Head Removal 83

Cylinder Head Installation 83

Cylinder Head Warp 84

Cylinder Head Cleaning 84

Valve Clearance Inspection 86

Valve Clearance Adjustment 87

Valve Removal 87

Valve Installation 87

Valve Guide Removal 88

Valve Guide Installation 88

Valve Seat Inspection 89

Measuring Valve-to-Guide Clearance (Wobble Method) 89

Valve Seat Repair 90

Seat Cutter Operating Cares 90

Marks Stamped On The Cutter 91

Cylinder Removal 95

Cylinder Installation 95

Piston Removal 95

Piston Installation 96

Piston Ring, Piston Ring Groove Wear 97

Piston Ring End Gap 97

Cylinder Inside Diameter 97

Piston Diameter 98

Boring, Honing 98

Carburetor Holder Installation 99

Exhaust Pipe, Muffler Removal 100

Exhaust Pipe, Muffler Installation 101

Clutch 102

Clutch Exploded View 103

Clutch Specifications 105

Clutch Special Tools And Sealant 106

Clutch Lever Free Play Inspection 107

Clutch Lever Free Play Adjustment 107

Clutch Lever Installation 108

Cable Lubrication 108

Right Engine Cover 109

Clutch Cover Removal 109

Clutch Cover Installation 109

Clutch Release Removal 109

Clutch Release Installation 110

Clutch Removal 111

Clutch Installation 111

Clutch Plate Wear, Damage Inspection 112

Clutch Plate Warp Inspection 112

Clutch Spring Free Length Measurement 113

Clutch Housing Finger Inspection 113

Clutch Hub Spline Inspection 113

Engine Lubrication System 114

Engine Lubrication System Exploded View 115

Engine Oil Flow Chart 117

Engine Lubrication System Specifications 118

Engine Lubrication System Special Tools And Sealant 119

Engine Oil Level Inspection 120

Engine Oil Change 121

Engine Oil Filter Change 121

Oil Pan Removal 122

Oil Pan Installation 122

Relief Valve Removal 122

Relief Valve Installation 122

Relief Valve Inspection 123

Oil Pump Removal 124

Oil Pump Installation 124

Oil Pump Disassembly 125

Oil Pump Assembly 125

Oil Screen Cleaning And Inspection 125

Oil Pressure Measurement 126

Engine Removal/Installation 127

Engine Removal/Installation Exploded View 128

Engine Removal/Installation Special Tool 129

Engine Removal 130

Engine Installation 131

Crankshaft/Transmission 132

Crankshaft/Transmission Exploded View 133

Crankshaft/Transmission Specifications 135

Crankshaft/Transmission Special Tools And Sealant 138

Crankcase Splitting 139

Crankcase Assembly 140

Clutch Housing/Primary Chain Removal 142

Clutch Housing/Primary Chain Installation 142

Primary Chain Guide Wear 142

Crankshaft Removal 143

Crankshaft Installation 143

Connecting Rod Removal 143

Connecting Rod Installation 143

Crankshaft/Connecting Rod Cleaning 144

Connecting Rod Bend/Twist 144

Connecting Rod Big End Side Clearance 145

Connecting Rod Big End Bearing Insert/Crankpin Clearance 145

Crankshaft Runout 147

Crankshaft Main Bearing Insert/Journal Clearance 147

Crankshaft Side Clearance 149

Balancer Removal 150

Balancer Installation 150

Balancer Shaft Bearing Insert/Journal Clearance 150

Balancer Shaft Bearing Insert Selection 152

Transmission 153

External Shift Mechanism Removal 153

External Shift Mechanism Installation 153

External Shift Mechanism Inspection 154

Transmission Shaft Removal 154

Transmission Shaft Installation 155

Transmission Shaft Disassembly 155

Drive Shaft Assembly 156

Output Shaft Assembly 157

Shift Drum And Fork Removal 158

Shift Drum And Fork Installation 159

Shift Drum Disassembly 160

Shift Drum Assembly 160

Ball And Needle Bearing Wear 161

Shift Pedal, Shift Pedal Linkage Removal 161

Shift Pedal, Shift Pedal Linkage Installation 161

Wheels/Tires 163

Wheels/Tires Exploded View 164

Wheels/Tires Specifications 165

Wheels/Tires Special Tools 166

Front Wheel Removal 167

Front Wheel Installation 167

Rear Wheel Removal 167

Rear Wheel Installation 168

Wheel Inspection 169

Spoke Inspection 169

Rim Inspection 170

Axle Inspection 170

Balance Inspection 170

Balance Adjustment 171

Air Pressure Inspection/Adjustment 172

Tire Inspection 172

Tire Removal 172

Tire Installation 173

Hub Bearing Removal 175

Hub Bearing Installation 175

Hub Bearing Inspection 176

Disassembly And Assembly 177

Lubrication 177

Final Drive 178

Final Drive Exploded View 179

Final Drive Specifications 180

Final Drive Special Tools 181

Drive Chain Slack Inspection 182

Drive Chain Slack Adjustment 182

Wheel Alignment Inspection/Adjustment 183

Drive Chain Wear Inspection 184

Drive Chain Lubrication 185

Drive Chain Removal 185

Drive Chain Installation 185

Drive Chain Replacement (EN500-C9) 186

Engine Sprocket Removal 189

Engine Sprocket Installation 189

Rear Sprocket Removal 190

Rear Sprocket Installation 190

Sprocket Wear Inspection 190

Rear Sprocket Warp Inspection 190

Coupling Bearing Removal 191

Coupling Bearing Installation 191

Coupling Installation 191

Coupling Bearing Inspection And Lubrication 192

Brakes 193

Brakes Exploded View 194

Brakes Specifications 196

Brakes Special Tool 197

Inside Circlip Pilers 197

Caliper Removal 198

Caliper Installation 198

Caliper Disassembly 198

Caliper Assembly 199

Fluid Seal Damage 200

Dust Seal And Cover Damage 200

Piston Cylinder Damage 200

Caliper Holder Shaft Wear 200

Brake Pad Removal 201

Brake Pad Installation 201

Brake Pad Lining Wear 201

Master Cylinder Removal 202

Master Cylinder Installation 202

Master Cylinder Disassembly 202

Master Cylinder Assembly 203

Master Cylinder Inspection (Visual Inspection) 203

Brake Disc Removal 204

Brake Disc Installation 204

Brake Disc Wear 204

Brake Disc Warp 204

Level Inspection 205

Brake Fluid Change 205

Bleeding The Brake Line 206

Brake Hose Inspection 208

Brake Hose Replacement 208

Brake Pedal Position Inspection 209

Brake Pedal Position Adjustment 209

Brake Pedal Free Play Inspection 209

Brake Pedal Free Play Adjustment 209

Brake Pedal Removal 210

Brake Pedal Installation 210

Brake Cable Lubrication 211

Cam Lever Angle Inspection 212

Cam Lever Angle Adjustment 212

Brake Panel Removal 212

Brake Panel Installation 212

Brake Panel Disassembly 213

Brake Panel Assembly 213

Brake Shoe Lining Wear 214

Brake Shoe Spring Inspection 214

Brake Camshaft And Camshaft Hole Wear 214

Brake Drum Wear 215

Brake Lubrication 215

Suspension 216

Suspension Exploded View 217

Suspension Specifications 219

Suspension Special Tools 220

Front Fork Removal 221

Front Fork Installation 221

Fork Oil Change 221

Front Fork Disassembly 223

Front Fork Assembly 224

Inner Tube Inspection 225

Dust Seal Inspection 226

Spring Tension 226

Spring Preload Adjustment 227

Rear Shock Absorber Removal 227

Rear Shock Absorber Installation 228

Rear Shock Absorber Wear 228

Bushing Wear 228

Swingarm Removal 229

Swingarm Installation 229

Swingarm Disassembly/Assembly 229

Swingarm Needle Bearing Lubrication 229

Steering 230

Steering Exploded View 231

Steering Special Tools 232

Steering Inspection 233

Steering Adjustment 233

Steering Stem, Stem Bearing Removal 235

Steering Stem, Stem Bearing Installation 236

Steering Stem Bearing Inspection And Lubrication 237

Grease Seal Deterioration Damage 237

Steering Stem Warp 237

Handlebar Removal 238

Handlebar Installation 238

Frame 239

Frame Exploded View 240

Seat Removal/Installation 242

Right Side Cover Removal 243

Right Side Cover Installation 243

Left Side Cover Removal 243

Left Side Cover Installation 243

Front Fender Removal 244

Front Fender Installation 244

Rear Fender Removal 244

Storage Case Removal 245

Storage Case Installation 245

Battery Case 246

Electrical System 247

Electrical System Parts Location 249

Electrical System Exploded View 250

Electrical System Specifications 255

Electrical System Special Tools And Sealant 256

Electrical System Wiring Diagram (United States And Canada) EN500-C1-C3 Model 258

Electrical System Wiring Diagram (United States And Canada) EN500-C1-C4 Model 262

Electrical System Wiring Diagram (United States And Canada) EN500-C4-C5 Model 263

Electrical System Wiring Diagram (Other Than United States And Canada) EN500-C4 - C7 Model 264

Electrical System Wiring Diagram (United States And Canada) EN500-C6 266

Electrical System Wiring Diagram (Other Than United States And Canada) EN500-C8 Model 268

Electrical System Precautions 270

Electrical Wiring Inspection 272

Battery 273

Electrolyte Level Inspection 273

Battery Condition 273

Battery Initial Charging 274

Battery Ordinary Charging 276

Battery Test Charging 277

Battery Troubleshooting Guide 278

Charging System 279

Alternator Rotor/Starter Clutch Removal 279

Alternator Rotor/Starter Clutch Installation 280

Alternator Stator Removal 281

Alternator Stator Installation 281

Regulator/Rectifier Removal 281

Regulator/Rectifier Output Voltage Inspection 281

Alternator Inspection 283

Alternator Output Voltage 283

Stator Coil Resistance 283

Rectifier Inspection 284

Regulator Inspection 284

Regulator Circuit Test-3rd Step 285

Charging System Circuit 285

Ignition System Safety Instructions 286

Crankshaft Sensor Removal 286

Crankshaft Sensor Installation 286

Crankshaft Sensor Inspection 286

Ignition Coil Removal/Installation 287

Ignition Coil Inspection 287

Spark Plug Removal/Installation 288

Spark Plug Cleaning, Inspection 288

Spark Plug Gap Inspection 288

IC Igniter Removal 289

IC Igniter Installation 289

IC Igniter Inspection 289

Diodes Inspection 290

IC Igniter Troubleshooting 292

Ignition System Circuit 293

Electric Starter System 294

Starter Motor Removal 294

Starter Motor Installation 294

Starter Clutch Sprocket Removal 295

Starter Clutch Sprocket Installation 295

Starter Motor Disassembly 295

Starter Motor Assembly 296

Starter Chain Guide Wear 296

Starter Clutch Inspection 297

Starter Relay Inspection 297

Brush Inspection 297

Brush Spring Inspection 297

Armature Inspection 298

Brush Plate Inspection 298

Electric Starter Circuit 299

Lighting System 300

Headlight Beam Horizontal Adjustment 300

Headlight Beam Vertical Adjustment 300

Headlight Bulb Replacement 300

Headlight Unit/Housing Removal 301

Headlight Unit Installation 301

Tail/Brake Light Bulb Replacement 301

Tail/Brake Light Lens Removal/Installation 301

Turn Signal Light Bulb Replacement 302

Turn Signal Relay Inspection 302

Headlight Circuit 303

Turn Signal Light Circuit 305

Cooling Fan System Circuit Inspection 306

Cooling Fan Motor Inspection 306

Radiator Fan Circuit 306

Meter Instruments Removal 308

Meter Instruments Installation 308

Meter Unit Disassembly 308

Bulb Replacement 308

Rear Brake Light Timing Inspection 309

Rear Brake Light Timing Adjustment 309

SwitcH Inspection 309

Switches And Sensors 310

Radiator Fan Switch Inspection 310

Water Temperature Switch Inspection 311

Junction Box Fuse Circuit Inspection 312

Starter Circuit/Headlight Relay Inspection 312

Diode Circuit Inspection 313

Junction Box Internal Circuit 314

30 Ampere Fuse Removal 315

Junction Box Fuse Removal 315

Fuse Installation 315

Fuse Inspection 315

Appendix 316

Troubleshooting Guide 317

Engine Doesn't Start, Starting Difficulty 317

Poor Running At Low Speed 317

Poor Running Or No Power At High Speed 318

Overheating 318

Over Cooling 319

Clutch Operation Faulty 319

Gear Shifting Faulty 319

Abnormal Engine Noise 319

Abnormal Drive Train Noise 320

Abnormal Frame Noise 320

Oil Pressure Warning Light Goes On 320

Exhaust Smokes Excessively 320

Brake Doesn't Hold 321

Battery Trouble 321

Nut, Bolt, And Fastener Tightness 323

Cable, Wire And Hose Routing 324

Model Application 337

Table Of Contents 338

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