Tool

Use a ratchet-type tool when installing the fork top bolt. This makes it unnecessary to remove the tool from the bolt whilst threading it in, thus making it easier to maintain a downward pressure on the spring. 8.7 Unscrew the steering stem bolt and remove the washer 8.2 The brake hose union is secured by two bolts 8.7 Unscrew the steering stem bolt and remove the washer 8.2 The brake hose union is secured by two bolts 8.8a Remove the locknut (A), adjuster ring (B) and the bearing cover (C)...

Fault Finding Equipment ref4i

Continuity check of rear brake light switch using a continuity tester Continuity check of front brake light switch using a meter - note split pins used to access connector terminals All of these instruments are self-powered by a battery, therefore the checks are made with the ignition OFF. As a safety precaution, always disconnect the battery negative (-ve) lead before making checks, particularly if ignition switch checks are being made. If using a meter, select the appropriate ohms scale and...

Info

27.3a Atmospheric temperature sensor (arrowed) 27.3b Carburettor temperature sensor (arrowed) 27.3a Atmospheric temperature sensor (arrowed) 27.3b Carburettor temperature sensor (arrowed) 1 The carburettor heater system fitted to UK ZR550 B4, B5 and B6 models, and to UK ZR750 C3, C4, C5 and D1 models incorporates a heater unit in each carburettor body, an atmospheric temperature sensor in the air filter housing and a relay. The ZR750 C3 and C4 models also have an oil temperature sensor and...

ZR550 models sixspeed transmission

transmission shafts, place the parts on a long rod or thread a wire through them to keep them in order and facing the proper direction. 2 Remove the needle bearing outer race from the left-hand end of the shaft, then remove the circlip and slide the needle bearing and thick thrust washer and the 2nd gear pinion off the shaft (see illustration). 3 Remove the circlip securing the 6th gear pinion, then slide the splined washer, the 6th gear pinion and its bush, and the splined washer off the...

Tools and Workshop Tips refh

3.11 Vernier component parts (linear gauge) 1 Clamp screws 3 Internal jaws 5 Sliding scale 7 Depth gauge 2 External jaws 4 Thumbwheel 6 Main scale In the example shown the item measures 55.92 mm (see illustration 3.12) 3.12 Vernier gauge reading of 55.92 mm 3.12 Vernier gauge reading of 55.92 mm 1 Clamp screw 5 Main scale 2 External jaws 6 Sliding scale 3 Internal jaws 1 Dial gauge In the example shown the item measures 55.92 mm (see illustration 3.12)

Inspection

11 Install the starter driven gear into the starter clutch (if removed) and, with the clutch face down on a workbench, check that the gear rotates freely in an anti-clockwise direction and locks against the rotor in a clockwise direction (see illustration). If it doesn't, replace the starter clutch. 12 Remove the needle bearing from the centre of the starter driven gear if it didn't come out with the secondary shaft (750 models only). Withdraw the starter driven gear from the starter clutch. If...

Preparing for storage

If repairs or an overhaul is needed, see that this is carried out now rather than left until you want to ride the bike again. Give the bike a good wash and scrub all dirt from its underside. Make sure the bike dries completely before preparing for storage. Remove the spark plug(s) and lubricate the cylinder bores with approximately a teaspoon of motor oil using a spout-type oil can (see illustration 1). Reinstall the spark plug(s). Crank the engine over a couple of times to coat the piston...

Bearing shell selection

8 Replacement bearing shells for the big-end bearings are supplied on a selected fit basis. Marks stamped on various components are used to identify the correct replacement bearings. The crankpin journal size marks (either a O or no mark) are stamped on the crankshaft web (see illustration 27.10a). The connecting rod size mark (either a O or no mark) is marked around the weight letter on the flat face of the connecting rod and cap (see illustration). 9 A range of bearing shells is available. To...

Exhaust System and Final Drive

Check that the exhaust mountings are secure and that the system does not foul any of the rear suspension components. Start the motorcycle. When the revs are increased, check that the exhaust is neither holed nor leaking from any of Its joints. On a linked system, check that the collector box is not leaking due to corrosion. Note that the exhaust decibel level (loudness of the exhaust) is assessed at the discretion of the tester. If the motorcycle was first used on or after 1st January 1985 the...

Abnormal driveline noise

Clutch housing friction plate clearance excessive (Chapter 2). Loose or damaged clutch pressure plate and or bolts (Chapter 2). Bearings worn. Also includes the possibility that the shafts are worn. Overhaul the transmission (Chapter 2). Gears worn or chipped (Chapter 2). Metal chips jammed in gear teeth. Probably pieces from a broken clutch, gear or shift mechanism that were picked up by the gears. This will cause early bearing failure (Chapter 2). Engine oil level too low. Causes a howl from...

REFMo Fault Finding Equipment

Measuring open-circuit battery voltage Float-type hydrometer for measuring battery specific gravity Measuring open-circuit battery voltage Float-type hydrometer for measuring battery specific gravity Before any electrical fault is investigated the battery should be checked. You'll need a dc voltmeter or multimeter to check battery voltage. Check that the leads are inserted in the correct terminals on the meter, red lead to positive (+ve), black lead to negative (-ve). Incorrect connections can...

S

1 Brake hose condition should be checked regularly and the hoses replaced at the specified interval (see Chapter 1). 2 Twist and flex the rubber hoses while looking for cracks, bulges and seeping fluid (see illustration). Check extra carefully around the areas where the hoses connect with the banjo fittings, as these are common areas for hose failure. 3 Inspect the metal banjo union fittings connected to the brake hoses. If the fittings are rusted, scratched or cracked, replace them. 4 The...

ZR750 fivespeed transmission

30.32e then slide the outer race over the bearing 38 Wash all of the components In clean solvent and dry them off. 39 Check the gear teeth for cracking chipping, pitting and other obvious wear or 30.32c . and the needle bearing onto the shaft 30.47a Slide the 4th gear pinion . . . 30.48a Slide the 3rd gear pinion onto the shaft 30.48b . . . and secure it with the circlip, then slide the thrust washer . 30.48a Slide the 3rd gear pinion onto the shaft damage. Any pinion that is damaged as such...

Storage ref29

Preventative, oil or a stabiliser added to the fuel, drain and flush the tank and dispose of the fuel sensibly. If no action was taken with the fuel tank prior to storage, it is advised that the old fuel is disposed of since it will go off over a period of time. Refill the fuel tank with fresh fuel. Oil all pivot points and cables. Check the tyre pressures. They will definitely need inflating if pressures were reduced for storage. Lubricate the final drive chain (where applicable). Remove any...

Jet sizes 550 models

Pilot jet Pilot air Needle jet Jet Cylinders 1 and 4 Cylinders 2 and 3 Main air jet Starter jet Pilot jet C1, C2, C3 and C4 Cylinders 1 and 4 Cylinders 2 and 3 Cylinders 1 and 4 Cylinders 2 and 3 Cylinders 1 and 4 Cylinders 2 and 3 Main air jet (gasoline) or any component containing it. Again, remember the possible presence of fumes before using electrical equipment. Always mop up any spilt fuel and safely dispose of the rag used. Any stored fuel that is drained off during servicing work must...

Excessive exhaust smoke

The ring may be broken or damaged, causing oil from the crankcase to be pulled past the piston into the combustion chamber. Replace the rings with new ones (Chapter 2). Cylinders worn, cracked, or scored. Caused by overheating or oil starvation. The cylinders will have to be rebored and new pistons installed (Chapter 2). Valve oil seal damaged or worn. Replace oil seals with new ones (Chapter 2). Valve guide worn. Perform a complete valve job (Chapter 2). Engine oil level...

Steering

9.6 Drawbolt arrangement for fitting 6 Press the new races into the head using a drawbolt arrangement (see illustration), or by using a large diameter tubular drift. Ensure that the drawbolt washer or drift (as applicable) bears only on the outer edge of the race and does not contact the working surface. Alternatively, have the races installed by a Kawasaki dealer equipped with the bearing race installing tools. 7 To remove the lower bearing from the steering stem, clamp the stem in a vice and...

Throttle cables

The fuel tap to the PRI position - fuel will flow into the tube. Wait for the fuel level to stabilise, then slowly lower the tube until the zero mark is level with the bottom edge of the carburettor body. Note Don't lower the zero mark below the bottom edge of the carburettor then bring it back up - the reading won't be accurate. 18 Measure the distance between the mark and top of the fuel level in the tube or gauge. This distance is the fuel level write it down on a piece of paper, screw in...

Idle fuelair mixture adjustment

1 Due to the increased emphasis on controlling motorcycle exhaust emissions, certain governmental regulations have been formulated which directly affect the carburation of this machine. In order to comply with the regulations, the carburettors on US models are sealed so they can't be tampered with. The pilot screws on other models are accessible, but the use of an exhaust gas analyser is the only accurate way to adjust the idle fuel air mixture and be sure the machine doesn't exceed the...

Disassembly

1 Remove the carburettors from the machine as described in the previous Section. Note Do not separate the carburettors unless this is absolutely necessary each carburettor can be dismantled sufficiently for all normal cleaning and adjustments while still in place on the mounting brackets. Dismantle the carburettors separately to avoid interchanging parts, or else store the parts from each in marked containers. 2 Unscrew and remove the top cover retaining screws (see illustration). Lift off the...

Haynes

To prevent the circlip from pinging away or from dropping into the crankcase, pass a rod or screwdriver, whose diameter is greater than the gap between the circlip ends, through the piston pin - this will trap the circlip if it springs out. l FA'M kl lf a piston pin is a tight fit in the piston bosses, soak a rag HINT in boiling water then wring it out and wrap it around the piston - this will expand the alloy piston sufficiently to release its grip on the pin. 16 Pistons - removal, Inspection...

Fault Finding Equipment ref39

Low compression will result in exhaust smoke, heavy oil consumption, poor starting and poor performance. A compression test will provide useful information about an engine's condition and if performed regularly, can give warning of trouble before any other symptoms become apparent. A compression gauge will be required, along with an adapter to suit the spark plug hole thread size. Note that the screw-in type gauge adapter set up is preferable to the Before carrying out the test, first check...

Technical Terms Explained ref

ABS (Anti-lock braking system) A system, usually electronically controlled, that senses Incipient wheel lockup during braking and relieves hydraulic pressure at wheel which is Aftermarket Components suitable for the motorcycle, but not produced by the motorcycle Allen key A hexagonal wrench which fits into a recessed hexagonal hole. Alternating current (ac) Current produced by an alternator. Requires converting to direct current by a rectifier for charging purposes. Alternator Converts...

Front wheel bearings

Note Always replace the wheel bearings in pairs. Never replace the bearings individually. Avoid using a high pressure cleaner on the wheel bearing area. 2 Speedometer 4 Speedometer drive gear housing drive Tips in the Reference section for more information about bearings. 6 If the bearings are of the unsealed type or are only sealed on one side, clean them with a high flash-point solvent (one which won't 1 Remove the wheel (see Section 14) (see illustration). 2 Set the wheel on blocks so as not...

Ignition system check

Caution The energy levels in electronic systems can be very high. On no account should the ignition be switched on whilst the plugs or plug caps are being held. Shocks from the HT circuit can be most unpleasant. Secondly, it is vital that the engine is not turned over or run with any of the plug caps removed, and that the plugs are soundly earthed (grounded) when the system is checked for sparking. The ignition system components can be seriously damaged if the HT circuit becomes isolated. 1 As...

Oil clearance check

10 Whether new bearing shells are being fitted or the original ones are being re-used, the connecting rod bearing oil clearance should be checked prior to reassembly. 11 Clean the backs of the bearing shells and the bearing locations in both the connecting rod and cap. 12 Press the bearing shells into their locations, ensuring that the tab on each shell engages the notch in the connecting rod cap (see illustration). Make sure the bearings are fitted in the correct locations and take care not to...

Fuel tank

1 All repairs to the fuel tank should be carried out by a professional who has experience in this critical and potentially dangerous work. Even after cleaning and flushing of the fuel system, explosive fumes can remain and ignite during repair of the tank. 2 If the fuel tank is removed from the bike, it should not be placed in an area where sparks or open flames could ignite the fumes coming out of the tank. Be especially careful inside garages where a natural gas-type appliance is located,...

Remove Front Wheel Zx11

1 Unscrew the knurled ring securing the speedometer cable to its drive housing on the left-hand side of the wheel hub, and detach the cable (see illustration). 2 Remove the left-hand brake caliper mounting bolts and slide the caliper off the disc (see illustration 3.2a). Support the caliper with a piece of wire or a bungee cord so that no strain is placed on its hydraulic hose. There is no need to disconnect the hose from the caliper. 3 Slacken the axle clamp bolt on the bottom of the...

REF22 MOT Test Checks

In the UK, all vehicles more than three years old are subject to an annual test to ensure that they meet minimum safety requirements. A current test certificate must be issued before a machine can be used on public roads, and is required before a road fund licence can be issued. Riding without a current test certificate will also invalidate your insurance. For most owners, the MOT test is an annual cause for anxiety, and this is largely due to owners not being sure what needs to be checked...

REF4 Tools and Workshop Tips

Work is made much easier by raising the bike up on a ramp - components are much more accessible if raised to waist level. The hydraulic or pneumatic types seen in the dealer's workshop are a sound investment if you undertake a lot of repairs or overhauls (see illustration 1.1). If raised off ground level, the bike must be supported on the ramp to avoid it falling. Most ramps incorporate a front wheel locating clamp which can be adjusted to suit different diameter wheels. When tightening the...

Kerosene In Zr550 Crankcase

Cam chain tensioner plunger bolt Nm Gearchange shaft centralising spring locating pin 20 Nm Gearchange mechanism cover bolts Nm The engine transmission unit is an air-cooled in-line four. The valves (two per cylinder) are operated by double overhead camshafts which are chain driven off the crankshaft. The engine transmission assembly is constructed from aluminium alloy. The crankcase is divided horizontally. The crankcase incorporates a wet sump, pressure-fed lubrication system which uses a...

Specifications

All other models 10Ah MF (maintenance-free) Electrolyte specific gravity - ZR550 B1, B2, B3 and B4 models 1.280 at 20 C Main Headlight Taillight Turn signal (later models only) Ignition (later models only) Horn (later models only) Accessories ZR550 (all models), ZR750 C1, C2 (UK) and ZR750 C1 to C3 ZR750 C3, C4, C5, D1 (UK), ZR750 C4 Sidelight (UK only) UK models US models UK models US models Instrument lights - US ZR550 B1 and B2 Speedometer and tachometer Warning Instrument lights - all other...

Yhm

1 Unscrew the two screws securing the tail light lens and remove the lens (see illustration). 8 Pull the bulbholder out of its socket in the base of the headlight (see illustration). Push the bulb down and twist it anti-clockwise to release it from the bulbholder (see illustration). 9 Install the new bulb in the bulbholder, then install the bulbholder by pressing it in. 10 Check the operation of the sidelight, then install the headlight rim into the shell and secure It with the screws (see...

Ref30 Fault Finding

This Section provides an easy reference-guide to the more common faults that are likely to afflict your machine. Obviously, the opportunities are almost limitless for faults to occur as a result of obscure failures, and to try and cover all eventualities would require a book. Indeed, a number have been written on the subject. Successful troubleshooting is not a mysterious 'black art' but the application of a bit of knowledge combined with a systematic and logical approach to the problem....

Zx11 Chain Adjustment

Spark Plug Electrode Adjuster

Fork oil drain screw Shock absorber lower mounting nuts Nm Maintenance schedule - ZR550 B & ZR750 C models Note The daily (pre-ride) checks at the beginning of the manual cover those items which should be inspected on a daily basis. Always perform the pre-ride inspection at every maintenance interval (in addition to the procedures listed). The intervals listed below are the intervals recommended by the manufacturer for the models covered in this manual. Your owner's handbook may have...

Abnormal frame and suspension noise

Low fluid level or improper viscosity oil in forks. This can sound like spurting and is usually accompanied by irregular fork action (Chapter 5). Spring weak or broken. Makes a clicking or scraping sound. Fork oil, when drained, will have a lot of metal particles in it (Chapter 5). Steering head bearings loose or damaged. Clicks when braking. Check and adjust or replace as necessary (Chapters 1 and 5). Fork yokes loose. Make sure all clamp pinch bolts are tight (Chapter 5). Fork tube bent....

Zr550 How To Change Oil Filter

Service Oil Filter Vn750

ZR550B-004001 to 012000 ZR550B-012001 to 022000 ZR550B-022001 to 030000 ZR550B-030001 to 036000 ZR550B-036001 on ZR750C-000001 to 018500 ZR750C-018501 to 035000 ZR750C-035001 to 040000 ZR750C-040001 on ZR750C-050001 on ZR750D-000001 on JKAZRFB1 LA000001 to 004000 JKAZRFB1 MA004001 on JKAZRFB1 *NA012001 to 022000 J KAZRFB1 'PA022001 on J KAZRDC1 'MA00001 to 018500 JKAZRDC1 *NA018501 on J KAZRDC1 PA035001 on The frame number is stamped on the steering head The engine number is stamped into the...

Zr 550 Clutch Cable Routing

Don't work in a garage where a natural gas-type appliance is present. If you spill any fuel on your skin, rinse it off immediately with soap and water. When you perform any kind of work on the fuel system, it is advisable to wear safety glasses and have a fire extinguisher suitable for a Class B type fire (flammable liquids) on hand. 1 The hoses should be replaced regardless of their condition. 2 Remove the fuel tank (see Chapter 3). Disconnect the fuel hoses from the fuel tap and from the...

Inside Tube Spring Bush

Inside Tube Spring Bush

1 Always dismantle the fork legs separately to avoid interchanging parts and thus causing an 6.3 Hose guide and cable guide bolt arrowed - 750 models 6.8 Fit the axle nut into the bottom of the left-hand fork 6.4 Top yoke fork clamp bolt arrowed . Note the alignment of the fork with the top yoke as an aid to installation 6.5 Bottom yoke fork clamp bolts arrowed accelerated rate of wear. Store all components In separate, clearly-marked containers see illustration . 2 Before dismantling the fork,...

Clutch cablef

18.22b Fit the dowels arrowed if removed, and a new gasket 20 Lubricate the release rod with molybdenum disulphide grease. On 750 models lubricate both sides of the release bearing and thrust washer with clean engine oil, then install them onto the release rod. Install the release rod into the back of the pressure plate so that the headed end protrudes from the front see illustration . 21 Install the pressure plate onto the clutch see illustration . Install the springs, then install the...

Zr 550 Clutch Torque Settings

15 Remove all traces of old gasket from the crankcase and clutch cover surfaces. 16 Slide the inner thrust washer, with its flat surface facing out, onto the end of the input shaft see illustration . 18.13 The release bearing on 550 models fit into the pressure plate 18.13 The release bearing on 550 models fit into the pressure plate 18.11 Measure the free length of the clutch springs 18.14a Clutch release lever alignment marks arrowed - 550 models 18.14b Clutch release lever alignment marks...

Poor handling or stability

Steering head bearing adjuster nut too tight. Check adjustment Chapter 1 . Bearings damaged. Roughness can be felt as the bars are turned from side-to-side. Replace bearings and races Chapter 5 . Races dented or worn. Denting results from wear In only one position e.g., straight ahead , from a collision or hitting a pothole or from dropping the machine. Replace races and bearings Chapter 5 . Steering stem lubrication inadequate. Causes are grease getting hard from age or being washed out by...

Poor running at low speeds

Check and recharge battery Chapter 8 . Spark plugs fouled, defective or worn out Chapter 1 Spark plug cap or HT wiring defective Chapters 1 and 4 . Spark plug caps not making contact. Incorrect spark plugs. Wrong type, heat range or cap configuration. Check and install correct plugs Chapter 1 . Ignition control defective Chapter 4 . Pulse generator coil defective Chapter 4 . Ignition HT coil s defective Chapter 4 . Pilot screws out of adjustment Chapter 3 . Pilot jet or...

Engine doesnt start or is difficult to start

Battery voltage low. Check and recharge battery Chapter 8 . Starter motor defective. Make sure the wiring to the starter is secure. Make sure the starter relay clicks when the start button is pushed. If the relay clicks, then the fault is in the wiring or motor. Starter relay faulty. Check it using the procedure in Chapter 8. Starter switch not contacting. The contacts could be wet, corroded or dirty. Disassemble and clean the switch Chapter 8 . Wiring open...

Abnormal engine noise

Carbon build-up in combustion chamber. Use of a fuel additive that will dissolve the adhesive bonding the carbon particles to the piston crown and chamber is the easiest way to remove the buildup. Otherwise, the cylinder head will have to be removed and decarbonized Chapter 2 . Incorrect or poor quality fuel. Old or improper fuel can cause detonation. This causes the pistons to rattle, thus the knocking or pinging sound. Drain the old fuel and always use the recommended grade fuel Chapter 3 ....

Kawasaki Zr 550 Sprcocket Cover Screws

1 Remove the clutch see Section 18 . 2 Remove the oil pump see Section 23 . 3 Before the secondary shaft is removed, check the primary chain slack by measuring the amount of up and down movement in the chain mid-way between the crankshaft and secondary shaft sprockets see illustration . If it exceeds the service limit specified, the 20.12 Fit the cover using a new gasket 1 Crankshaft 2 Secondary shaft 3 Primary chain slack 21.6 Remove the shaft bearing cap and discard its O-ring 21.8 On 750...

Zr550 Loose Yellow Black Wire

Motorcycle Relay Checking

27.14a System control unit - 550 models 27.14b System control unit - 750 models 27.14a System control unit - 550 models 27.14b System control unit - 750 models 12 The atmospheric temperature sensor is threaded into the front of the air filter housing see illustration 27.3a , the oil temperature sensor is threaded into the crankcase below the pulse generator assembly cover, and the carburettor temperature sensor is threaded into the no. 2 carburettor in place of one of the joining bracket screws...

Initial startup after overhaul

1 Make sure the engine oil level is correct see Daily pre-ride checks . 2 Pull the plug caps off the spark plugs and insert a spare spark plug into each cap. Position the spare plugs so that their bodies are earthed grounded against the engine. Turn the ignition switch ON and make sure the kill switch is in the RUN position, then crank the engine over with the starter until the oil pressure light goes off which indicates that oil pressure exists . Turn off the ignition. Remove the spare spark...

Steering and Suspension

With the front wheel raised off the ground, rotate the steering from lock to lock. The handlebar or switches must not contact the fuel tank or be close enough to trap the rider's hand. Problems can be caused by damaged lock stops on the lower yoke and frame, or by the fitting of non-standard handlebars. When performing the lock to lock check, also ensure that the steering moves freely without drag or notchiness. Steering movement can be impaired by poorly routed cables, or by overtight head...

Tools and Workshop Tips refi9

8.8 Assemble the chain riveting tool over one pin at a time and tighten it fully 8.10 Typical chain size and type marking 9.5 Cutting a coolant hose free with a sharp knife The second and third digits of the chain size relate to the width of the rollers, again in imperial units, eg the 525 shown has 5 16 inch 7.94 mm rollers see illustration 8.11 . 8.9 Pin end correctly riveted A , pin end unriveted B 9.1 Hoses can be clamped with an automotive brake hose clamp 9.4 or thick card and...

The Green Meanies

Kawasaki is a company of contradictions. Japanese manufacturers but the biggest company, it was the last of the four to make and market motorcycles yet it owns the oldest name in the Japanese industry, and it was the first to set up a factory in the USA. Kawasaki Heavy Industries, of which the motorcycle operation is but a small component, is a massive company with its heritage firmly in the old heavy industries like shipbuilding and railways nowadays it is as much involved in aerospace as in...

Zr550 Torque Setting For Cylinder Head

Kawasaki R500 Camshaft Timing

Caution Once you start to remove the tensioner bolts, you must remove the 9.24a Apply sealant to the areas shown arrowed 9.24b then fit the cover using a new gasket 9.26 Unscrew the cap bolt and withdraw the spring and stopper 9.24b then fit the cover using a new gasket tensioner all the way and reset it before tightening the bolts. The tensioner extends itself and locks in place, so if you loosen the bolts partway and then retighten them, the tensioner or cam chain will be damaged. Do not...

Tools and Workshop Tips refs

Fastener head types are either of hexagonal, Torx or splined design, with internal and external versions of each type see illustrations 2.1 and 2.2 splined head fasteners are not in common use on motorcycles. The conventional slotted or Phillips head design is used for certain screws. Bolt or screw length is always measured from the underside of the head to the end of the item see illustration 2.11 . 2.1 Internal hexagon Allen A , Torx B and splined C fasteners, with corresponding bits 2.1...

REF46 Technical Terms Explained

Rebore Providing a new working surface to the cylinder bore by boring out the old surface. Necessitates the use of oversize piston and rings. Rebound damping A means of controlling the oscillation of a suspension unit spring after it has been compressed. Resists the spring's natural tendency to bounce back after being compressed. Rectifier Device for converting the ac output of an alternator into dc for battery charging. Reed valve An induction system commonly used on two-stroke engines....

Fuel level check

Army Checking Fuel Level

15 Lightly clamp the carburettor assembly in the jaws of a vice. Make sure the vice jaws are lined with wood. Set the fuel tank next to the vice, but at an elevation that is higher than the carburettors resting on a box, for example . Connect a hose from the fuel tap to the fuel inlet fitting on the carburettor assembly -make sure the fuel tap is in the ON or RES position. 16 Attach Kawasaki service tool no. 57001-1017 to the drain fitting on the bottom of one of the carburettor float chambers...

REF42 Fault Finding Equipment

Checking for voltage at the rear brake light power supply wire using a meter Checking for voltage at the rear brake light power supply wire using a meter 1 First identify the relevant wiring circuit by referring to the wiring diagram at the end of this manual. If other electrical components share the same power supply le are fed from the same fuse , take note whether they are working correctly - this is useful information in deciding where to start checking the circuit. 2 If using a meter,...

And float height check

Note When reassembling the carburettors, be sure to use all new O-rings and seals. Do not overtighten the carburettor jets and screws as they are easily damaged. 1 Install the choke plunger and spring into the carburettor body and tighten the nut to 9.1a Fit the inner plastic washers 9.1c making sure it locates correctly onto each plunger 9.1 d Install the screws with the outer plastic washers 9.1 e Hook the spring around the take-off adapter 9.1f then fit the caps and the vacuum hose 9.1a Fit...

Zr550 Get Rid Of Clutch Switch

Sidestand switch troubles may be caused by a sticking switch plunger due to the ingress of road dirt - peel back the rubber gaiter and spray the plunger with a water dispersant aerosol. 10 Reconnect the switch wiring connector see illustration 22.7 . 11 Check the operation of the neutral light. 12 Install the sprocket cover and the gearchange linkage arm, aligning the marks made on removal. 1 The sidestand switch is mounted on the frame just ahead of the sidestand pivot see illustration 23.8 ....

Tools and Workshop Tips refi3

Install the bolts nuts in their correct location and secure them lightly. Their threads must be clean and free of any old locking compound. Unless specified the threads and flange should be dry - oiled threads are necessary in certain circumstances and the manufacturer will take this into account in the specified torque figure. Similarly, the manufacturer may also specify the application of thread-locking compound. Tighten the fasteners in the specified sequence until the torque wrench clicks,...

I

1 The procedure for checking and adjusting the idle speed is the same as for the other 1 The procedure for synchronising the carburettors is the same as for the other models see Section 6 . 18.14b Shim selection chart - ZR550 - intake valves 1 Remove the fuel tank and the tank bracket 2 Unscrew the two screws securing the air filter cover to the filter housing see illustration . Remove the cover and withdraw the filter from the housing see illustrations . 3 Tap the filter on a hard surface to...

Brakes Wheels and Tyres

On drum brakes, check the angle of the operating lever with the brake fully applied. Most drum brakes have a wear indicator pointer and scale. With the wheel raised off the ground, apply the brake then free it off, and check that the wheel is about to revolve freely without brake drag. On disc brakes, examine the disc itself. Check that it is securely mounted and not cracked. On disc brakes, view the pad material through the caliper mouth and check that the pads are not worn down beyond the...

Fuel and exhaust systems

Air filter - cleaning and replacement see Chapter 1 Air filter housing - removal and installation 12 Air suction valves US models - general information 15 Carburettor overhaul - general information 5 Carburettors - disassembly, cleaning and inspection 7 Carburettors - reassembly, float height and fuel level check 9 Carburettors - removal and installation 6 Carburettors - separation and joining 8 Carburettors - synchronisation see Chapter 1 Choke cable - removal and Evaporative emission control...

Yjw

A Warning The dust created by the brake system may contain L A asbestos, which is harmful to your health. Never blow it out with compressed air and don't inhale any of it. An approved filtering mask should be worn when working on the brakes. 1 On all except ZR750 D models, unscrew the brake caliper mounting bolts and slide the caliper off the disc see illustration 3.2a . Remove the outer pad from the caliper body, noting how the protrusion on each end of the pad locates against the guide see...

REF24 MOT Test Checks

Inspect the area around the fork dust seal for oil Bounce the rear of the motorcycle to check rear leakage arrow suspension operation Worn suspension linkage pivots arrows are usually the cause of play in the rear suspension Inspect the area above and around the front fork oil seals see illustration 6 . There should be no sign of oil on the fork tube stanchion nor leaking down the slider lower leg . On models so equipped, check that there is no oil leaking from the anti-dive units. On models...

Kawasaki 57001-1099

Clues to a faulty regulator are constantly blowing bulbs, with brightness varying considerably with engine speed, and battery overheating, necessitating frequent topping up of the electrolyte level. 7 Connect a multimeter set to the 0-20 volts dc scale voltmeter across the terminals of the battery positive lead to battery positive terminal, negative - lead to battery negative - terminal . Start the engine, then turn on the lights UK models and note the reading obtained at idle speed - it should...

Kawasaki Zr 550 Gauge

Maximum gauge reading as the amount of runout in the shaft. Note The reading obtained will be total runout at that point -some manufacturers specify that the runout figure is halved to compare with their specified runout limit. Endfloat sideplay measurement requires that the gauge is mounted securely to the surrounding component with its probe touching the end of the shaft. Using hand pressure, push and pull on the shaft noting the maximum endfloat recorded on the gauge see illustration 3.19 ....