Kawasaki Vulcan 500 (2000-2009) Maintenance Schedule and Service Intervals

This is the maintenance schedule with associated service intervals for the 2000-2009 Kawasaki Vulcan 500 and Vulcan 500 LTD.

The Kawasaki Vulcan 500 is powered by a 498cc, liquid cooled, DOHC, parallel twin engine. The engine is paired with a 6-speed transmission and it drives the rear wheel by chain.

The Vulcan 500 was superseded by the Kawasaki Vulcan S.

Maintenance Schedule for Kawasaki Vulcan 500 LTD

Below is the maintenance schedule for the Kawasaki Vulcan 500 LTD.

The following is the list of maintenance operations and to be done on this motorcycle with a time or distance interval — whichever comes earlier.

The maintenance for the Kawasaki Vulcan 500 LTD is broken into two sections: Emission Related, and Non-Emission Related.

OperationEvery800 km (500 mi)5000 km (3000 mi)10000 km (6000 mi)15000 km (9000 mi)20000 km (12000 mi)25000 km (15000 mi)30000 km (18000 mi)
Emission Related:
Carburetor synchronization — check †
Idle speed–adjust
Throttle grip play–check †
Spark plug–clean and gap †
Valve clearance–check †
Air suction valve – check †
Air cleaner element –clean
Air cleaner element –replace5 cleanings
Fuel system–check
Evaporative emission control system (c)–check †
Non-Emission Related:
Battery elecrolyte level – check †month
Brake play – check †
Brake light switch — check †
Brake lining or pad wear– check †
Brake fluid level — check †month
KBrake fluid – change2 years
Clutch – adjust
KSteering –check †
Drive chain wear–check † #
Nuts, bolts, and fasteners tightness — check †
KSpoke tightness and rim runout – check †
Tire wear–check †
Engine oil–changeyear
Oil filter–replace
General Lubrication–perform
KFront fork oil–change
KSwingarm pivot — lubricate
KBrake camshaft – lubricate2 years
KCoolant–change2 years
Radiator hoses, connections–check †year
KSteering stem bearing–lubricate2 years
KMaster cylinder cup and dust seal–replace2 years
KCaliper piston seal and dust seal–replace2 years
KBrake cable – replace2 years
KBrake hose –replace4 years
KFuel hose–replace4 years
Drive chain–lubricate #Every 600 km (400 mi)
Dive chain slack–check † #Every 1000 km (600 mi)


K: Should be serviced by an authorized Kawasaki dealer
*: For higher odometer readings, repeat at the frequency interval established here
†: Replace. add. adjust, or torque if necessary.
(c): California model only
#: Service more frequently when operation in severe conditions: dusty, wet, muddy, high speed, or frequent starting/stopping

Tyre size and tyre pressure for the Kawasaki Vulcan 500

The Kawasaki Vulcan 500 has the following tyres and tyre sizes standard:

Front100/90-19M/C 57S200 kPa/28 psi
Rear140/90-15M/C 70S225 kPa/32 psi
Kawasaki Vulcan 500 tyre pressure

General information about the Kawasaki Vulcan 500

The Vulcan 500 is powered by a 498cc, liquid-cooled, four-stroke, DOHC, eight-valve parallel twin-engine.

It is styled with a sharp front fender curved around a 19-inch front wheel, quick-grab handlebars, and a one-piece seat. The teardrop tank with the speedometer complements the engine configuration.

The automatic cam chain tensioner maintains precise timing without maintenance, and keeps the cam chain running quietly and reliably.

The gear-driven balancer reduces engine vibration for a super-smooth ride.

A 32mm CVK semi-flat slide carburetor gives quick throttle response, precise fuel metering provides uniform power delivery at all engine speeds.

The straight-flow exhaust designed to boost low and mid-range power, tuned pipes enhance low-speed pulling power.

The single piston pin-slide caliper on the front produces quick, sure stops.

The chrome-plated wire spoke wheels with a narrow 100/90-19 front tire and beefy 140/90-15 rear tire fit the Vulcan 500’s traditional cruiser styling.

Manual for the Kawasaki Vulcan 500

Maintenance Schedule Screenshot From Manual 2000-2009 Kawasaki Vulcan 500 LTD.
User manual screenshot for the 2000-2009 Kawasaki Vulcan 500 LTD

The above maintenance schedule comes directly from the user’s manual for the 2009 Kawasaki Vulcan 500 LTD, which is available here.

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