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Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.

To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. Excessive amount may block engine oil passages and cause serious dam- age. If there is any doubt as to the condition of them, replace them with new ones.

Overall Width mm Overall Height 1 mm Wheelbase 1 mm Road Clearance mm 4. Mqnual Height mm The initial maintenance is vitally important and must not be neglected. An insufficiently tightened bolt or vjlcan may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider.

Use this table for only the mqnual and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. Pilot Screw washer 3. If the free play is incorrect, adjust the throttle cable.

If cable movement is not free manula lubricating, if the cable is frayed [B], or if the cable housing is kinked [C], replace the cable. If the intake vacuum difference between the two cylinders exceeds the limit, adjust the synchronization. Engine Vacuum Synchronization Less than 2. If the fuel level cannot be adjusted by this method, the float or the float valve [C] is damaged.

If they are not, ownere the mounting screws and align the carburetors on a flat surface.

2006 Kawasaki Vulcan 500 LTD — Owner’s Manual

Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbure- tor with a cleaning solution. If any of the O-rings or diaphragms are not in good con- dition, replace them. Turn the ignition switch OFF. Make owjers the area is well-ventilated and free from any source of flame or sparks; If the dampers are damaged or deteriorated, replace them. Al- though no adjustments are required, a thorough visual manuql spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.


Special Tool and Sealant Cooling System Pressure Testing Water Temperature Switch T6: Coolant Filter Body A: Austria, Germany, France, Maual, Korea, 5.

Kawasaki Bond Silicone Sealant: If the coolant is brown, iron or steel parts are rusting. In either case flush the cooling system. Wait until it cools down. Coolant on tires will make them slippery and can cause an accident and injury. Always replace the gasket with a new one, if it is damaged. Torque – Coolant Drain Plug: The maxi- mum pressure is kPa 1. Apply silicone sealant to the area [A] where the mating surface of the crankcase contacts the water pump hous- ing gasket.



Sealant – Kawasaki Bond Silicone Sealant: Torque – Water Pump Cover Bolts: If the surface is corroded, or if the blades are damaged, replace the impeller. If any one of the parts is damaged, replace the mechani- cal seal as a unit.

The radiator fan may start even if the ignition switch is off. Never touch the radiator fan until the radiator fan connector is disconnected.

They must be smooth and clean for the radiator cap to iawasaki properly. Suspend an ac- curate thermometer [B] in the water so that the heat sen- sitive portions [C] are located in almost gulcan same depth. Main Oil Pipe Removal Main Oil Pipe Installation Follow the specific tightening sequence. Closed coil end is downwards. United States, Switzerland, Austria, Ko- 2. Piston Ring End Gap: Valve Guide Arbor, 5. Torque – Cylinder Head Cover Bolts: The push rod does not return to its kawasaaki position once it moves out to take up cam chain slack.


Ob- serve all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway. The plastigage indicates the clearance by the amount it is compressed and widened when the parts are assembled.

Valve Clearance when cold 0. Valve Seating Surface Width 0.

This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.

The rings should fit perfectly parallel to the groove sur- faces. If not, the piston must be replaced. If the measurement is under the service limit, replace the piston. The projection [A] faces upwards.

If necessary, replace the gaskets with new ones. Clutch Lever and Cable Clutch Lever Free Play Inspection Clutch Lever Free Play Adjustment Starter Lockout Switch T1: Apply high temperature grease. Apply a non-permanent locking agent. Apply molybdenum disulfide grease. Friction Plate Thickness 2. Friction And Steel Plate Warp If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: Clutch Housing Finger Inspection Engine Oil Flow Chart Special Tools and Sealant Engine Oil and Oil Filter Engine Oil Level Inspection Oil Pan and Relief Valve Oil Passage Plug T8: Oil Pump Drive Gear T1: Oil Pressure Relief Valve T4: Then stop the engine.

Torque – Oil Pump Mounting Bolts: Special Tool – Jack: Apply liquid gasket – silver.

Apply a thin coat of molybdenum disulfide grease. Connecting Rod Twist — — — 0. Balancer Shaft Bearing Insert Selection: Bearing Insert Crankcase Bearing