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EN500
Kawasaki EN500 User Manual
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2
Table of Contents
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
4
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Kawasaki EN500 Specifications
General
Displacement
498 cc
Front Brake
Single disc
Rear Brake
Drum
Front Tire
100/90-19
Front Suspension
Telescopic fork
Rear Suspension
Dual shocks
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