Zr550 Loose Yellow Black Wire

27.9 System control unit test

27.9 System control unit test connector and remove the relay

27.14a System control unit - 550 models

27.14b System control unit - 750 models

27.13a Sensor relay - 550 models

27.13b Sensor relay - 750 models

27.13c Disconnect the relay wiring

27.13a Sensor relay - 550 models

27.13b Sensor relay - 750 models

27.13c Disconnect the relay wiring connector and remove the relay

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 (see illustration 27.3b). Disconnect the wiring connector and unscrew the sensor (in the case of the oil temperature sensor, first drain the engine oil -

13 The relay is mounted behind the right-hand side panel on 550 models, and under the fuel tank behind the regulator/rectifier on 750 models (see illustrations). Remove the side panel (see Chapter 7) or the fuel tank (see Chapter 3) for access. Disconnect the relay wiring connector and remove the relay (see

14 The system control unit is mounted behind the ignition control unit on 550 models and behind the left-hand side panel on 750 models (see illustrations). Remove the ignition control unit (see Chapter 4) or the side panel (see Chapter 7). Disconnect the wiring at the connector and pull the unit and its rubber sleeve off its mounting lugs.

15 Installation is the reverse of removal. Make sure all wiring connectors are secure.

Apply a silicone sealant to the threads of the oil temperature sensor.

28 Horn - check and replacement

Check

1 The horn is mounted in front of the engine below the steering head.

2 Unplug the wiring connectors from the horn (see illustration). Using two jumper wires,

28.2 Disconnect the horn wiring connectors apply battery voltage directly to the terminals on the horn. If the horn sounds, check the switch (see Section 21) and the wiring between the switch and the horn (see the wiring diagrams at the end of this Chapter).

3 If the horn doesn't sound, replace it.

Replacement

4 The horn is mounted in front of the engine

5 Unplug the wiring connectors from the horn (see illustration 28.2), then unscrew the bolts securing the horn bracket and remove the horn from the bike (see illustration).

28.5 The horn bracket is secured by two bolts (arrowed)
Motorcycle Relay Checking
29.4 Starter relay test meter (A) and battery (B) connections

6 Install the horn and securely tighten the bolts. Connect the wiring connectors to the horn.

29 Starter relay -

check and replacement ^S

Check

1 If the starter circuit is faulty, first check the fuse (see Section 5).

2 The starter relay is located behind the left-hand side panel. Remove the side panel for access (see Chapter 7). Pull back the rubber cover on the starter motor lead, then unscrew the nut securing the starter motor lead to its terminal and disconnect the lead (see illustration). Making sure that the disconnected lead is well clear of its terminal, switch the ignition ON and ensure the engine kill switch is in the RUN position, the transmission is in neutral and the clutch pulled in, then press the starter switch. The relay should click.

3 If the relay doesn't click, switch off the ignition and remove the relay as described below; test it as follows.

4 With the relay removed from the bike, set a multimeter to the ohms x 1 scale and connect it across the relay's starter motor and battery

29.8 Disconnect the wiring connector (A), unscrew the nuts (B) and detach the leads

lead terminals. Using a fully-charged 12 volt battery and two insulated jumper wires, connect the positive (+) terminal of the battery to the yellow/red wire terminal of the relay, and the negative (-) terminal to the black/yellow wire terminal of the relay (see illustration). At this point the relay should click and the multimeter read 0 ohms (continuity). If this is the case the relay is proved good. If the relay does not click when battery voltage is applied and indicates no continuity (infinite resistance) across its terminals, it is faulty and must be replaced.

5 If the relay is good, check for battery voltage between the yellow/red wire and the black/yellow wire when the starter button is pressed. Check the other components in the starter circuit as described in the relevant sections of this Chapter. If all components are good, check the wiring between the various components (see the wiring diagrams at the end of this book).

Replacement

6 Remove the seat and the left-hand side panel (see Chapter 7).

7 Disconnect the battery terminals, remembering to disconnect the negative (-) terminal first.

8 Disconnect the relay wiring connector, then unscrew the two nuts securing the starter motor and battery leads to the relay and

30.2a Unscrew the bolts (arrowed) and remove the top cover ...

detach the leads (see illustration). Remove the relay with its rubber sleeve from its mounting lugs on the frame. 9 Installation is the reverse of removal, ensuring the terminal screws are securely tightened. Connect the negative (-) lead last when reconnecting the battery.

30 Starter motor -

removal and installation

Removal

1 Remove the seat (see Chapter 7). Disconnect the battery negative (-) lead.

2 On 550 models, unscrew the two bolts securing the starter motor top cover and lift off the cover (see illustration). Slacken the upper starter motor mounting bolt, then remove the lower cover (see illustration).

3 On 750 models, unscrew the gearchange linkage arm pinch bolt and remove the arm from the shaft, noting any alignment marks (see illustration 22.2a). If no marks are visible, make your own before removing the arm so that it can be correctly aligned with the shaft on installation. Unscrew the bolts securing the engine sprocket cover to the crankcase and remove the cover (see illustration 22.2c). Unscrew the two bolts

30.2b ... then slacken the upper mounting bolt and remove the lower cover

29.2 Detach the starter motor lead (arrowed) from the relay

30.3 Removing the top cover on 750 models

30.4 Unscrew the nut and detach the starter motor lead

30.13 Install the engine sprocket cover

30.8 Fit a new O-ring (arrowed)

30.3 Removing the top cover on 750 models

30.4 Unscrew the nut and detach the starter motor lead

30.6 ... and remove the starter

30.5 Unscrew the mounting bolts ...

Installation

30.6 ... and remove the starter securing the starter motor top cover, noting how the collar and rubber damper fit, and remove the cover (see illustration).

4 Peel back the rubber cover and unscrew the nut securing the starter cable to the motor (see illustration).

5 Unscrew the two bolts securing the starter motor to the crankcase (see illustration).

6 Slide the starter motor out from the crankcase and remove it from the machine (see illustration).

7 Remove the O-ring on the end of the starter motor and discard it; a new one must be used.

10 Install the starter motor bolts. On 550 models, tighten only the lower bolt, leaving the upper one slack for the lower cover. On 750 models, tighten both bolts to the torque setting specified at the beginning of the Chapter.

11 Connect the starter cable to the motor and secure it with the nut (see illustration 30.4). Make sure the rubber cover is correctly seated over the terminal.

12 On 550 models, install the lower cover so that the front mounting fits around the upper starter motor bolt (see illustration 30.2b).

Tighten the bolt to secure the cover. Install the upper cover and tighten its bolts.

13 On 750 models, install the top cover, making sure the rubber damper and collar are correctly fitted, then install the bolts (see illustration 30.3). Install the sprocket cover and the gearchange linkage arm, aligning the marks made previously, and tighten the pinch bolt securely (see illustration).

14 Connect the battery negative (-) lead and install the seat.

8 Install a new O-ring on the end of the starter motor and ensure it is seated in its groove (see illustration). Apply a smear of engine oil to the O-ring to aid installation. Make sure that the mating surfaces between the starter motor mounting points and the crankcase are clean to ensure a good earth (ground).

9 Manoeuvre the motor into position and slide it into the crankcase (see illustration 30.6). Ensure that the starter motor teeth mesh correctly with those of the starter idle/reduction gear.

30.13 Install the engine sprocket cover

30.5 Unscrew the mounting bolts ...

30.8 Fit a new O-ring (arrowed)

31.3a Starter motor long bolts (arrowed) - 31.3b Starter motor long bolts (arrowed) -550 models 750 models

31.2 Note the alignment marks between the main housing and the covers

31.3a Starter motor long bolts (arrowed) - 31.3b Starter motor long bolts (arrowed) -550 models 750 models

31.2 Note the alignment marks between the main housing and the covers

31.6a Unscrew the nut (arrowed) and remove the washers ... 31.6b ... then remove the brushplate assembly

31 Starter motor - disassembly, inspection and reassembly

Disassembly

1 Remove the starter motor (see Section 30).

2 Note the alignment marks between the main housing and the front and rear covers as an aid to installation, or make some of your own if they are difficult to see (see illustration). Also make a mark to identify which way up the housing fits.

3 Unscrew the two long bolts and withdraw them from the starter motor (see illustrations). Discard their O-rings (550 models only) as new ones must be used. Remove the rear cover from the motor along with its O-ring. Discard the O-ring as a new one must be used. Remove the shims from the rear end of the armature shaft or from inside the rear cover.

4 Remove the front cover from the motor along with its O-ring. Discard the O-ring as a new one must be used. On 550 models, remove the washer(s) from the front end of the armature shaft and the seal protector from inside the front cover, noting their correct fitted locations (see illustration 31.19a). On

750 models, remove the dividing plate, noting how the notch in its perimeter locates over the lug on the inside of the main housing (see illustration 31.19c). Also note the locating pin between the ring gear and the front cover, and take care not to lose it (see illustration 31.19d). The notch in the perimeter of the front cover also locates over the lug on the inside of the main housing. Remove the shims from the front end of the armature shaft.

5 Withdraw the armature from the main housing.

6 Noting the correct fitted location of each component, unscrew the terminal nut and remove the insulating washers (see illustration). On US/Canada ZR750 C1, C2 and C3 models, remove the brushplate assembly and terminal bolt from the main housing. On all other models, remove the brushplate assembly and terminal bolt from the rear cover (see illustration).

7 Lift the brush springs and slide the brushes out from their holders, noting how they fit.

Inspection

8 The parts of the starter motor that are most likely to require attention are the brushes. Measure the length of the brushes and compare the results to the brush length listed in this Chapter's Specifications (see illustration). If any of the brushes are worn beyond the service limit, replace the brush assembly with a new one. If the brushes are not worn excessively, nor cracked, chipped, or otherwise damaged, they may be re-used. Also check the brush springs, making sure they provide a firm pressure on the brush when installed.

9 Inspect the commutator bars on the armature for scoring, scratches and discoloration (see illustration). The commutator can be cleaned and polished with crocus cloth, but do not use sandpaper or

31.9 Check the commutator bars as described emery paper. After cleaning, wipe away any residue with a cloth soaked in electrical system cleaner or denatured alcohol. Clean out the mica grooves between the commutator bars. Measure the diameter of the commutator and compare it to the specifications. If the commutator has worn to below its service limit, the armature must be replaced. 10 Using an ohmmeter or a continuity test light, check for continuity between the commutator bars (see illustration). Continuity should exist between each bar and all of the others. Also, check for continuity between the commutator bars and the armature shaft (see illustration). There should be no continuity (infinite resistance) between the commutator and the shaft. If the checks indicate otherwise, the armature is defective.

11 Check for continuity between each brush and the terminal bolt. There should be continuity (zero resistance). Check for continuity between the terminal bolt and the housing (when assembled). There should be no continuity (infinite resistance).

12 Check the front end of the armature shaft for worn, cracked, chipped and broken teeth. If the shaft is damaged or worn, replace the armature. On 750 models, similarly check the ring gear in the front cover and the drive pinion on the front of the cover. The drive pinion is secured by a circlip, and the chamfered side of the pinion teeth must face out (see illustration).

13 Inspect the end covers for signs of cracks or wear. Inspect the magnets in the main housing and the housing itself for cracks.

14 Inspect the insulating washers and front cover oil seal (550 models) for signs of damage and replace them if necessary.

Terminal End Brush
31.16 Install the brushplate and terminal bolt and fit the washers as shown

Reassembly

15 Slide the brushes back into position in their holders on the brushplate and, on all except US ZR750 C1, C2 and C3 models, place the brush spring ends onto the brushes. On US ZR750 C1, C2 and C3 models, locate the spring end onto the top of the brush holder so that there is no pressure on the spring. This makes installation of the armature much easier.

16 Fit the inner rubber insulator on the terminal bolt, then insert the bolt through the rear cover (main housing on US ZR750 C1, C2 and C3 models) and install the brushplate assembly in the rear cover (main housing on US ZR750 C1, C2 and C3 models) making sure its tab is correctly located in the slot in the cover or housing (see illustration). Fit the O-ring and the washers over the terminal and secure it with the nut.

17 On all except US ZR750 C1, C2 and C3 models, slide the shims over the rear end of the armature shaft (see illustration). Insert the armature into the offset opening in the brushplate. locating the commutator bars against the brushes, then press the brushes back into the holders until the armature shaft

31.17a Fit the shims onto the shaft...

31,10a Continuity should exist between the commutator bars 31.10b There should be no continuity between the commutator bars and the armature shaft

31,10a Continuity should exist between the commutator bars 31.10b There should be no continuity between the commutator bars and the armature shaft

31.12 Check the drive pinion on 750 models

31.17b ... then install the armature in the rear housing ...

31.18b ... then fit the housing over the armature...

end locates in its hole in the cover (see illustrations). Take care not to damage the brushes. On US ZR750 C1, C2 and C3 models, insert the armature into the main housing, then locate the spring ends onto the brushes so that the brushes are pressed onto the commutator. On all models, check that each brush is securely pressed against the commutator by its spring and is free to move easily in its holder.

18 Fit a new O-ring onto each end of the main housing (see illustration). On all except US ZR750 C1, C2 and C3 models, slide the housing over the armature, aligning the marks made on disassembly (see illustration). On US ZR750 C1, C2 and C3 models, slide the shims over the rear end of the armature shaft, then fit the end cover onto the main housing, aligning the marks made on disassembly.

19 On 550 models, apply a smear of grease to the lips of the front cover oil seal. Fit the washer(s) onto the shaft and the seal protector onto the front cover, making sure that the tabs on the seal protector locate correctly (see illustration). Install the cover, aligning the marks made on removal. On 750 models, fit the shims onto the front end of the armature shaft, then fit the dividing plate, locating the notch in its perimeter over the lug on the inside of the main housing. Check that the locating pin is installed in the notch between the perimeter of the ring gear and the front cover (see illustration). Fit the front cover onto the housing, aligning the lug on the inside of the main housing with the notch in the perimeter of the ring gear (see illustration).

31.17c ... and locate the commutator against the brushes

31.18c ... aligning the marks noted or made on removal

31.19b On 750 models, fit the washers onto the shaft...

31.19d Make sure the locating pin is in place ...

20 On 550 models, slide the lockwasher and a new O-ring onto each of the long bolts (see illustration). On all models, check the marks

31.18a Fit new O-rings onto the main housing .. .

31.19a On 550 models, fit the washers onto the shaft and the seal protector onto the front cover

31.19c ... then install the dividing plate, aligning the notch with the lug (arrowed)

31.19e ... then fit the front cover, aligning the lug (A) with the notch (B)

made on removal are aligned, then install the long bolts and tighten them securely (see illustration). On 550 models, make sure the

31.20a On 550 models, do not forget the O-ring and washer on each long bolt

flat side of the lockwasher locates correctly against the body of the rear cover (see illustration 31.3a).

21 Install the starter motor (see Section 30).

32 Charging system testing -

general information and precautions

1 If the performance of the charging system is suspect, the system as a whole should be checked first, followed by testing of the individual components. Note: Before beginning the checks, make sure the battery is fully charged and that all system connections are clean and tight.

2 Checking the output of the charging system and the performance of the various components within the charging system requires the use of a multimeter (with voltage, current and resistance checking facilities).

3 When making the checks, follow the procedures carefully to prevent incorrect connections or short circuits, as irreparable damage to electrical system components may result if short circuits occur.

4 If a multimeter is not available, the job of checking the charging system should be left to a Kawasaki dealer.

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