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Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done. Periodic Maintenance Chart.1-12 Torque and Locking Agent. 1-16 Unit Conversion Table.1-21. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. Apply them sparingly. Excessive amount may block engine oil passages and cause serious dam- age. (11) Press When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit. If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening. An insufficiently tightened bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to the rider. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads. G: Apply grease. If the free play is incorrect, adjust the throttle cable.If the intake vacuum difference between the two cylinders exceeds the limit, adjust the synchronization.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. WARNING Clean the element in a well-ventilated area, and take care that there are no sparks or fame anywhere near. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;. Cooling System Pressure Testing.Flushing.
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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. 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 function properly. The push rod does not return to its original 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. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off. There is no UP or DOWN to the rails. The rings should fit perfectly parallel to the groove sur- faces.If the measurement is under the service limit, replace the piston. WARNING Install the clamp screws horizontally. Clutch Lever Installation.Cable Lubrication.Right Engine Cover. Clutch Cover Removal. G: Apply high temperature grease. WARNING To avoid a serious burn, never touch the engine or exhaust pipe during clutch adjustment. WARNING Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 34.2 mm (1.346 in.) Service Limit: 33.1 mm (1.303 in.) Clutch Housing Finger Inspection. Engine Oil and Oil Filter.Engine Oil Level Inspection.Engine Oil Change.Oil Filter Change. Oil Pan and Relief Valve.
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WARNING Clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Crankcase Splitting.LG: Apply liquid gasket - silver. M: Apply a thin coat of molybdenum disulfide grease. O: Apply engine oil. SS: Apply silicone sealant. Sealant - Kawasaki Bond (Liquid Gasket - Silver): 92104 -002 CAUTION Do not apply liquid gasket around the crankshaft main bearing inserts and balancer shaft inserts. The clearance may exceed the standard slightly, but it must not be less than the min- imum in order to avoid bearing seizure. Be sure that all parts are put back in the correct sequence and facing the proper direction, and that all circlips and washers are properly in place. Front Wheel Installation.Rear Wheel Removal.Rear Wheel Installation. Wheel Inspection.Spoke Inspection.Rim Inspection.Axle Inspection.Balance Inspection. Adjust the tire air pressure according to the specifications if necessary. Air Pressure (when cold) Up to 97.5 kg 200 kPa Front (215 lb) load. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so that the disc does not touch the ground. A chain that breaks or jumps off the sprock- ets could snag on the engine sprocket or lock the rear wheel, severely damaging the motorcycle and causing it to go out of control. R: Replacement Parts. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol, for cleaning brake parts. Air, however, is easily compressed. If it does not, adjust the rear brake cam lever angle.Replace them if necessary. If the spring of either fork leg is shorter than the service limit, it must be replaced. Rear Shock Absorbers (see Rear Shock Absorber Re- moval).G: Apply grease. L: Apply a non-permanent locking agent. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
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Special Tools - Head Pipe Outer Race Press Shaft: 57001 -1075 Head Pipe Outer Race Driver, 46.5: 57001. AT: Austria Model CA: Canada Model US: United States Model. Starter Motor 11. 30 A Main Fuse 12. If the specific gravity is below 1.200, the battery needs to be charged. CAUTION Always remove the battery from the motorcycle for changing.The readings should show nearly battery voltage when the en- gine speed is low, and, as the engine speed rises, the readings should also rise. A short or open in one of the coil wires will result in either a low output or no output at all. Do not touch the spark plugs, ignition coils, or spark plug leads while the engine is running, or you could receive a severe electrical shock. CAUTION Do not disconnect the battery leads or any other electrical connections when the ignition switch is. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used, the IC igniter will be damaged. Main Fuse 30 A 2. Ignition Switch 8. Diodes 14. Battery 3. Engine stop Switch 9. Neutral Switch 15. IC Igniter 4. Starter Button 10. Replace the starter motor with a new one if the commu- tator diameter is less than the service limit. If there is not close to zero ohm, the brush plate has an open. Starter Motor 2. Engine Stop Switch 7. Ignition Fuse 10A 12. Starter Relay 3. Starter Button 8. Starter Lockout Switch 13. Main Fuse 30A 4. In these models, the headlight does not go on when the igni- tion switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turned off. Headlight Switch 7. Rear Left Turn Signal Light 3. Front Left Turn Signal Light 11. Main Fuse 30 A 4. If the fan turns, inspect the fan switch. If the fan does not turn, inspect the following. If a meter is left upside down or sideways for any length of time, it will malfunction. The brake light should go on as specified.
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If it does not, replace the brake light switch. The relays and diodes can not be removed.It Crankshaft sensor trouble is meant simply as a rough guide to assist Ignition coil trouble the troubleshooting for some of the more Ignition or engine stop switch shorted. Also, check to see that each cotter pin is in place and in good condition.Notice it differs from that of right side. 3. Clamp 4. Coolant Filter 5. Coolant Filter Housing (Set the coolant filter housing parallel to the outer side of the frame.) 6. VIEW C: Run the throttle cable to the head side over the main harness and right handlebar switch lead.) 2. Rear Brake Switch Lead 3. Throttle Cables 19. Clamp (Clamp the brake cable together 4. Ignition Switch Connector with the brake switch lead run outside of 5. Insert the hose till its white-painted mark 3. Hose (Blue) main harness.Run the hoses inside the 2. Run the hose into the collar. swingarm. Position the white-painted 4. Kawasaki Vulcan 500 Maintenance Manual How to take out Vulcan 500 Carburetor Pt. 500 B2620 B2920 Operators. Humped Comal Item 676535 Tractor with 76SH Scraper. 2017 Honda Rebel 500 ABS. Manual For Kawasaki 2017 Vulcan 500. See More Komatsu Manuals at http: It will help the ope - shipbuilding, education and fabrication industries, the Aspect 375 REPAIR MANUAL - This is a COMPLETE Shop Maintenance Manual for the KOMATSU WA250PT-3MC PARALLEL TOOL CARRIER. Manual For Kawasaki 2017 Vulcan 500 from facebook.FranceRobert Speck SwitzerlandJames Spencer Tractor with 76SH Scraper Springfield, Stalwart, Standard, Standard-Modern, Stanko, Stanley, Star Tool. Manual For Kawasaki 2017 Vulcan 500 download.Manual For Kawasaki 2017 Vulcan 500 dropbox upload. Kawasaki Vulcan 500 Service Manual. Refine. Jump to Halfords Web of lowering springs, shocks, Springfield, Stalwart, Standard, Standard-Modern, main categories Jump For. Kawasaki En500 Vulcan 500 Ltd Service Repair Manual.
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Starter Relay 6. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on when the engine starts running and stays on even if the engine stalls. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands. But, motorcycles turn with a bank additionally, and so have a smaller steer angle. This makes difficult to adopt an automobile type turn signal canceling system because of inaccurate operation in motorcycles. Main Fuse 30 A in Starter Relay 3. The fan may start even if the ignition switch is off.The vehi- cle speed that corresponds to the input frequency will be displayed when a short wave form such as the one show in the diagram is input. During the speedometer inspection with an oscillator, verify that the digital meter reading increases. If it does not increase, replace the digital meter assembly.If there is any problem, replace the digital meter assembly. Ignition Fuse 10 A 6. If there is continuity in one direction (forward direction) but no continuity (infinity) in the reverse direction, the diode is normal. The relays and diodes can not be removed.Rear Brake Reservoir Cover 9. Rear Master Cylinder 14. Cotter Pin shown. Visit AoPS Online j Books for Grades 5-12 Online Courses Beast Academy Engaging math books and online learning for students ages 8-13. Visit Beast Academy j Books for Ages 8-13 Beast Academy Online AoPS Academy Nationwide learning centers for students in grades 2-12. Visit AoPS Academy j Find a campus Sign In Online Learn More Enroll FAQ Books Learn More 2A 2B 2C 2D 3A 3B 3C 3D 4A 4B 4C 4D 5A 5B 5C 5D All Books T-shirt FAQ For Schools Resources Planning Placement Tests Printables Virtual Backgrounds FAQ Ask Us. Play Want a live instructor for your Beast Academy student. Enroll in AoPS Academy A Complete Math Curriculum Recommended for Ages 8?13 A Complete Math Curriculum Recommended for Ages 8?
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