Kawasaki Vulcan 500 LTD manual

Kawasaki Vulcan 500 LTD
8.7 · 31
PDF manual
 · 351 pages
English
manualKawasaki Vulcan 500 LTD

8-18 CRANKSHAFT/T RANSMISSION

Crankshaft/Connecting Rods
NOTE
Do not turn the crankshaft during clearance measure-
ment.
Remove the lower crankcase half and measure the plas-
tigage width [A] to determine the bearing insert/journal [B]
clearance.
Crankshaft Main Bearing Insert/Journal Clearance
Standard: 0.020 0.044 mm (0.0008 0.0017 in.)
Service Limit: 0.08 mm (0.0032 in.)
If the clearance is within the standard, no bearing insert
replacement is required.
If the clearance is between 0.044 mm (0.0017 in.) and the
service limit 0.08 mm (0.0032 in.), replace the bearing in-
serts [A] with inserts painted blue [B] Check insert/journal
clearance with a plastigage. The clearance may exceed
the standard slightly, but it must not be less than the min-
imum in order to avoid bearing seizure.
If the clearance exceeds the service limit, measure the
diameter of the crankshaft main journal.
Crankshaft Main Journal Diameter
Standard: 35.984 36.000 mm (1.4167 1.4173 in.)
Service Limit: 35.96 mm (1.4157 in.)
If any journal has worn past t he service limit, replace the
crankshaft with a new one.
If the measured journal diameters are not less than the
service limit, but do not coincide with the original diameter
markings on the crankshaft, write a new mark on it.
Crankshaft Main Journal Diameter Ma rks
None: 35.984 35.992 mm (1.4167 1.4170 in.)
1: 35.993 36.000 mm (1.4170 1.4173 in.)
: Crankshaft Main Journal Diameter Marks, “1” mark or
no mark.
Put the lower crankcase half on the upper crankcase half
without bearing inserts, and tighten the case bolts to the
specified torque and sequence (see Crankcase Assem-
bly).
Measure the crankcase main bearing bore diameter, and
mark the upper crankcase half in accordance with the
bore diameter.
NOTE
The mark already on the upper crankcase half should
almost coincide with the measurement.
Crankcase Main Bearing Bore Diameter Marks
:
39.000 39.008 mm (1.5354 1.5357 in.)
None:
39.009 39.016 mm (1.5358 1.5361 in.)
□□□□:
Crankcase Main Bearing Bore Diameter
Marks,
”markornomark.

View the manual for the Kawasaki Vulcan 500 LTD here, for free. This manual comes under the category motorcycles and has been rated by 31 people with an average of a 8.7. This manual is available in the following languages: English. Do you have a question about the Kawasaki Vulcan 500 LTD or do you need help? Ask your question here

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Number of questions: 6
V
VagoDecember 11, 2022

What is the screw like that the engine has on top of the engine on one side of the gear on the outside?

What is the screw like that the engine has on top of the engine on one side of the gear on the outside?
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D
daniel jimenezMarch 27, 2024

Hi in the compartment where the stator goes, is it normal to have oil or does it have a seal to prevent that?

Hi in the compartment where the stator goes, is it normal to have oil or does it have a seal to prevent that?
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C
CodyMay 30, 2023

What to do when your motorcycle won’t start

S
ShaneJune 3, 2023

Can't find the drain bolt on my 94 vulcan 500

Can't find the drain bolt on my 94 vulcan 500
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Robinson Guerra March 4, 2023

Qué medidas tiene el manubrio de la Vulcan 500 modelo 1993

K
KennySeptember 24, 2023

Does a800 Vulcan have a fuesbox

The Kawasaki Vulcan 500 LTD is a motorcycle that was produced by the Japanese manufacturer Kawasaki from 1990 to 2009. It falls under the category of cruiser motorcycles and is designed for riders who prefer a more relaxed and comfortable riding experience. The Kawasaki Vulcan 500 LTD is equipped with a liquid-cooled, 498cc parallel twin engine. This engine configuration provides a balanced power delivery and contributes to the motorcycle's smooth and manageable performance. It features a six-speed transmission, allowing for precise and smooth gear changes. With a relatively lightweight design and a low seat height, the Kawasaki Vulcan 500 LTD offers excellent maneuverability and ease of handling. This makes it an ideal choice for riders who are new to motorcycles or prefer a more manageable ride. In terms of suspension, the Kawasaki Vulcan 500 LTD features a front telescopic fork and rear twin shock absorbers. These suspension components are designed to provide a comfortable and stable ride, absorbing uneven road surfaces and minimizing rider fatigue. The Kawasaki Vulcan 500 LTD is equipped with a disc brake on the front wheel and a drum brake on the rear wheel, ensuring reliable and efficient braking performance. It also features a fuel capacity of approximately 4.0 gallons, allowing for a decent cruising range. Overall, the Kawasaki Vulcan 500 LTD is a reliable and practical cruiser motorcycle, suitable for riders who prioritize comfort, smooth performance, and ease of handling.

General
BrandKawasaki
ModelVulcan 500 LTD
Productmotorcycle
LanguageEnglish
FiletypeUser manual (PDF)

Can't find the answer to your question in the manual? You may find the answer to your question in the FAQs about the Kawasaki Vulcan 500 LTD below.

How do I convert miles into kilometres?

1 mile equals 1.609344 kilometers and 1 kilometer equals 0.62137119 miles.

What is the difference between E10 and E5 petrol?

E10 petrol consists of up to ten per cent ethanol while E5 petrol will contain less than five per cent ethanol. As a result, the percentage of E10 petrol is lower than that of E5 petrol, making it less bad for the environment.

How often should I replace the oil filter on my Kawasaki engine?

An oil filter must be replaced every 6000 kilometres (approx. 4000 miles) for most engines.

How often should I change the oil of my Kawasaki engine?

The oil must be changed every 6000 kilometres (approx. 4000 miles) for most engines.

How do I remove rust from my Kawasaki motorcycle?

1. Soak the rusty part in vinegar until completely soaked through. 2. Let the vinegar work on the rust for 24 hours. 3. Remove the rust with a wire brush or aluminium foil.

How do I check and adjust the tire pressure on my Kawasaki Vulcan 500 LTD?

To check and adjust tire pressure, you need to use a tire pressure gauge and locate the recommended pressure range specified by the manufacturer (usually found on the tire's sidewall). Use a reliable air pump to add or release air until the pressure is within the recommended range.

What should I do if my Kawasaki Vulcan 500 LTD won't start?

Firstly, ensure the motorcycle is in neutral and the engine kill switch is set to "on." Check the battery to ensure it has sufficient charge. If the battery is fine, check for any loose or corroded connections in the ignition circuit. If the issue persists, it would be best to consult a qualified technician.

How do I properly adjust the clutch lever on my Kawasaki Vulcan 500 LTD?

Adjusting the clutch lever requires locating the adjuster nut, often found near the clutch lever perch. Loosening or tightening this nut will change the lever's position. Find the position that provides a comfortable reach while still engaging the clutch effectively.

How do I change the engine oil on my Kawasaki Vulcan 500 LTD?

Start by warming up the motorcycle's engine. Next, locate the oil drain plug underneath the engine and use a suitable wrench to remove it. Allow the old oil to drain completely. Then, remove the oil filter and replace it with a new one. Finally, reinstall the drain plug and fill the engine with the recommended amount and type of fresh oil.

How do I adjust the rear suspension on my Kawasaki Vulcan 500 LTD?

To adjust the rear suspension, locate the preload adjuster on the rear shock absorbers. Turning the adjuster clockwise increases the preload, providing stiffer suspension, while turning it counterclockwise decreases the preload, resulting in a softer ride. Find the appropriate setting that suits your riding preferences and weight.

Is the manual of the Kawasaki Vulcan 500 LTD available in English?

Yes, the manual of the Kawasaki Vulcan 500 LTD is available in English .

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