Kawasaki 454LTD, LTD450, Vulcan 500, Ninja 250 Repair Manual 1985-2007

The 1985-2007 Kawasaki 454LTD, LTD450, Vulcan 500, Ninja 250 DIY repair manual by Haynes, covers:

• Kawasaki 454LTD and LTD450 (EN450), 1985-1990
• Kawasaki Vulcan 500 (EN500), 1990-2007
• Kawasaki Ninja 250 (Ninja, Ninja R, EX250), 1986 to 2007

Like all Haynes motorcycle manuals, this service guide will help you maintain your bike in top running condition. Plus, if at any time you need to perform major repairs, such as rebuilding the engine or transmission, this manual will be indispensable for getting the job done right.

Book Excerpt: 1985-2007 Kawasaki 454LTD, LTD450, Vulcan 500, Ninja 250 Repair Manual MAJOR ENGINE REPAIR: GENERAL NOTE

1. It is not always easy to determine when or if an engine should be completely overhauled, as a number of factors must be considered.
2. High mileage is not necessarily an indication that an overhaul is needed, while low mileage, on the other hand, does not preclude the need for an overhaul. Frequency of servicing is probably the single most important consideration. An engine that has regular and frequent oil and filter changes, as well as other required maintenance, will most likely give many miles of reliable service. Conversely, a neglected engine, or one which has not been broken in properly, may require an overhaul very early in its life.
3. Exhaust smoke and excessive oil consumption are both indications that piston rings and/or valve guides are in need of attention. Make sure oil leaks are not responsible before deciding that the rings and guides are bad. Refer to Chapter 2C and perform a cylinder compression check to determine for certain the nature and extent of the work required.
4. If the engine is making obvious knocking or rumbling noises, the connecting rod and/or main bearings are probably at fault.
5. Loss of power, rough running, excessive valve train noise and high fuel consumption rates may also point to the need for an overhaul, especially if they are all present at the same time. If a complete tune-up does not remedy the situation, major mechanical work is the only solution.

CAMSHAFTS

1. Inspect the cam bearing surfaces of the head and the bearing caps. Look for score marks, deep scratches and evidence of spalling (a pitted appearance).
2. Check the camshaft lobes for heat discoloration (blue appearance), score marks, chipped areas, flat spots and spalling (see illustration). Measure the height of each lobe height listed in this Chapter's Specifications. If damage is noted or wear is excessive, the camshaft must be replaced.
3. Next, check the camshaft bearing oil clearances with Plastigage, referring to the Tools and Workshop Tips section at the end of this manual. Clean the camshafts, the bearing surfaces in the cylinder head and the bearing caps with a clean, lint-free cloth, then lay the cams in place in the cylinder head, with the cam timing marks positioned correctly for camshaft installation (see Chapter 2A or 2B). Engage the cam chain with the cam gears, so the camshafts don't turn as the bearing caps are tightened.

Subject: 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Kawasaki 454LTD, LTD450, Vulcan 500, Ninja 250 service, maintenance, and repair instructions. ISBN-10: 1620922347 | ISBN-13: 9781620922347| Haynes 2053