Kawasaki ZR550 and 750 Zephyr Fours '90 to '97

HAYNES SERVICE & REPAIR MANUAL KAWASAKI~ ZR550 &750 ZePhyr Fours '90 to '97 Whatever your area of interest, Haynes h...

Author: John Haynes

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HAYNES SERVICE & REPAIR MANUAL

KAWASAKI~ ZR550 &750 ZePhyr

Fours '90 to '97

Whatever your area of interest, Haynes have got it covered ... From Car Servke and Repair Manuals

1OCk. Ie< Ihey also had a 750 co lour. code-named New YorkSI""".alrJ"W)$lreadylo~landllwasa

double, rather than ling ... ov ... head cam

:::._B:~;;~t;: =~~::=I~o~ The ,&suit was thll ZI,unvelled at thll 1972 Cologne Show. II w!lS a bikaslraightoot ofthllll3memould as the 1-1 1, seare stories sproodal>out unmanageablepowee coelerm·wpeeber\elitlQfproorH!linbikedesignintl>e

br\tIgOUltMorOWllfetroblk"but Kawasaki IIIdtllectUCialac2vent8(l8ofl>eoog thenofirst and "'aped lhe f8W!Ifd$. NOotllw.1ItrO came

....,p/lasMIl>eZt herilage illerl wa,.painl

int~ t ... ~

=~earlit"-'lhI6~or7!;o!n the

~ Hono tlh ,.erylemabrown.ndor p noe

Thefint550, theBt,go1 that lavo...it"80s accessory the lour-into-.......Ila"s' .. stanOardAlOl'lgwilhdigotalignition.oiIcocW. aIIo)I.wingIng . ....,.piggybadcshod<s.1lw19Qk.aIIo)I ......... ndthr.,.dI""br.k ... 8o/Io:lglhMlo!onIOlltandardZtwouldhalo-. OOOIIyoualDtolfl'lOlW)l back int980.The750 II"tlhe_goodin but w a sr~ tI)o~.ItQe.Ij)QIew type 0 1 motOtcycla ~r In many COOOlfiel ,lherider ..tumingtobikHalt • • klngat>seno;e. n..Hso-called ·bom·~.1n could Immed~tety to the Z~ and, crucially. round them

. biIe Kawallkl IrkIrmIIIonSerYlolllndKelEdgelorLlflPlYlng ~~and toPhiFloweriIor

CO'O.

photography. The

introduction,·KRwasakI·TheGraerl~·

wM wnnenb'j J ullllnRylW.

About this Manual heaimdlhllmanuallstohelpyouoet the beat ...aMI lrom you- motorcyde. ~

T

cando ... In-.tWlys. lt canhelp

youdllddewhalworkmusl l:ltac.n.._" you choose to II done b ~. deII'-: It

1\11.,

pnw;oasinlormatlOflandproced""", lor

roullna maint_ . - and .-vicIno: and it

!::'-~=c~.;..:It:=~ ~

=.:

trqIrInI-.g.'.OurIa. No other bi ~ , took partin the . . .e\J"0 DOom although laler modaIa Iik, the Suzuki BlfHiitaand Triumpfl Speed Triples did ... popuIorise lhe idN 01 an .....11Ihod bike.

.,.,·90s

Thay"'fIO t thesamoolhing.TheZ~can

tract III anceslry d"et eccuncy ot Inlor_ lIon gr. .... In thll ma ".,e l, bul

~= ~~:::-ir procedures to

motorcycle manu/ecluraB make a he.alionl enddeaig ncha fl9lS duri ng thtproduction

We hope you use till maouaJ to tacl::ts· such as brake pads.clu\ch

~~~::e g~~:I$;.,:~~' ~ec~:~: ~~be~: ~~~o~sd~~th~h~"P~~5a~~: Itlalthe» do contaio

"""""t""

•

Aemerrberatalltimesthatpetr,"iShlghfy flarnmable . Never smoI<e or have any kind 01

~:;:~.~I~: t~~;:'d:::~;";~"~~";'e t~: spartyanelec1r1cal short-dn:uit.Dy two matalS!6IacesCOlltactirlg eacllother , by careless US9 of Toots. or even by static electricilybo,rittupinyOUl !x>dyur'lnof lh" luel

(eanh) terminalbeloreW<Jenus;ngcleaninQflllldsandoolveo1s. read lh,inslrucl>OOSCa ,efully.N
."",",.

The battery • Neve< caUM a Sjlatk, Or allow a na~ed IiQI1tr>eatth8ve1licle·sbaltery.llwII!normally be g iving 0 11 a certain amount 01 hyd rogen gas. which is hlghfy e"Pklsive

when charging thebaUeg or being cran ked,

r:.;::~~~si ~~~::~::,:: a~a~~~:o~~ ~ n l1lonsYSlemisused, t heoecondary(HT)

voItageh.muc:h higher aod coukl prove tala/

Identification numbers Frame and engine numbers The frame selial number fs siamped lnlo the righi-hand side oltha sle.ing head. The engme number is stamped into the top of the rightIlandsideolthecrankcase,behlndthecylinderblock..8o!hoft'~8houIdbe'eeordedandkeptin.safeplae.lI01heycanbe

fII'Ilished to lawenlofcement otIlc:iaIs In the event 01 a Iheft. There is abo • C3Jburenor iOentifoealicwl number on the side of each carburetlor 000y. The Iramtl serial numb&Mlerefittlld).

e Check thll the clutCh lev.. operates smoothly and with the COI1'ecl lmount 0'

IrHlllaYI_CIIapI.I).

Fuel:

• C~k Ihll lIMo bfa~e peds h a ve nol worn down to or beyond t MIf w .... , limit - t h.. e mual be a t Ie&II1 mmOI I",ingtell 00 each bral<epad(_Chapt. l j. • Check thaI tt>tenginelhutsottwl>enlhe klswitcllil;opwlt.:l.

. Tl'Oall'lltv...."OO';OOS , but check that you have IfIO\lOh I\Iet to complete yourjoofrwry, It you nollcellign,ot Tuetteak&g8-'ICt,Tylhe

ca..lnvnedioot...,.. . . ENlQyou...,IhIICOO"IIC'tgmd8_ ,... - _ CNpt. 3 Specilicatoons.

0. 12

Daily (pre-ride) checks

5 Tyres Tyre care: • Check the lyres carefully for cuts. tears, embedded nails or other sharp objects and excessive wear. Operation of the motorcycle with excessively worn lyres is extremely hazardous, as traction and handling are directly affected. • Check the condition 01 the tyre valve and ensure the dust cap is in place.

• Pick oul any stones or nails which may have become embedded in the lyre tread. II

left, they will eventually penetrate through the casing and cause a puncture. • If tyre damage is apparent, or unexplained loss of pressure is experienced, seek the advice of a lyre fitting specialist withou t delay.

Tyre tread depth: • At the time of wri ting UK law requires that tread depth must be at least 1 mm over 3/4 01 the tread breadth all the way around Ihe tyre, with no bald patches. Many rid9fs, however, consider 2 mm tread depth minimum to be a

2 The correct pressures: • The tyres must be checked when cold , not immediately af19f riding. Note thai !Ow tyre pressures may cause the tyre to slip on the rim ()( come off. High lyre pressures will cause aooormaltread wear and unsafe handling.

Measure tread depth at the centre of the lyre using a tread depth gauge.

• Use an accurate pressure gauge. • Proper air pressure will increase tyre life and provide maximum stability and ride comfort. Front Rear

....28 psi (2.0 Bar) ... . .. 32 psi (2.2 Bar)

safer limit . Kawasaki recommend following minimum tread depths.

the

Front . . ... , mm Rear· below 80 mph (130 km/h) ....2 mm Rear· above 80 mph (130 km / h) .•3 mm • Many tyres now incorporate wear IndicalOf'S in the tread. Find the wear indicat()( pointer on the lyre sidewall (this will vary according to the

tyre filted) to locate the indicator bar; replace the tyre if the tread has worn down to the bar.

3

Tyre tread wear indicator bar location marking (arrowed) - usually either an arrow, a triangle or the letters TWI on the sidewall.

,.,

Chapter 1 Routine maintenance and servicing Contents MMe'-cleaning . ... . AJrti ~ er·replac em ent

AJr!ilt ... ~

. ..... . . .. 21 ... . .. .... 29

- draining(750mod el5)

a

Airsuction.alves - check(IJS~,) . . 4 Battery - charging ", ... ... .. . . . . .. ..... .. " .. ... ""ChapterS

SM1ery- eiedrolylele . ... check(ZR5508 1, 82, 93&0084)

17

~~:=:::'=!:alreplac~;·seec.~.~~~ BrailefhM - char>ge

8,aI<ehoses - r"lllacement . . &aI<epads - wearchecJ< .

&akesystem · check ,_. ' . CarbureUors- syn.c:llrOnisabon.. Clutch-check .. C)'li'lde< head ..... ts and boIts tightnesscheck(ZA5500Bar>dZR750C) ClrM!cha;"'-cleaningand luoocatiQr>

~::'.! : ::"~~::;c~~~J~Slment Engine - cylir1deC$jnr""'alfn.c1ditionlo/flep~ /jsf8d)1'heInf8f\{"""b'st9db&low8re llleinlelW1sre~

by the manufactumr for the models co vtNed in ttlis manual. You r o wner·s IlIJndbool< may Mllft d ifferttnt imefVlHs if your modtJI is nct sptK:ifiealty coventdbytrnsl7WW8l. ffindOllbr, check with a KawasaJOdeaJet.

Every 6000 miles (t or twelve months

Daily (pre-ride)

o See 'Daily (pre-ride) checks' at the beg inning of th is manual.

a 000 km)

c.."y our aJJI/7$itllmslJlld$r rh63000mlle{5000hm)checl(JOlXlOlecIr, p/mfhlJ fo/lowing:

o Replace theairfilt8f"(SectiOn 29). o Change the brak e nuid (Section 30).

O Re-g rease the steering head bearings (Section 31).

Every 18 000 miles (30 000 km) or two years c.."yootllRfllfJ iJems under tM6IXJOmiItt ( JOOOOkm)cIwJck,

p/m thefollowing:

o Change the f ront fork oil (Section 33). Every two years

o

Replace the brake master cylinde!" and caliper seals (Section 34).

Every four years

o Replace the brak e hoses (Section 35). o Replace the fuel hoses (Section 36). Non-scheduled maintenance

o Check the headlight aim (Section 37). o Check the wheel bearings (Section 38).

D Check the cyl inder compression (Sect ion 39). D Check the engine oil pressure (Section 40) ..

Maintenance & servicing "5 Maintenance schedule - ZR750 D model Note: 71I6rJ4J1y{ple-ride)c/Iec/o;s. tlhe~ningotllle ll'l8 nua1CC>'e1"!hoseltemswlVchMou/dt>elnspectfld"" 8 d11l1ybMIs, A/Ways~rhe ~ride inspection 111 _ ,>, ma/n!ot1omrun oilhecha;n (BM lllua'ratiOt1).YOU wiIIptobablyliod lhalasyoulumooeadju.ter

.....

~=

..

. .. andt/>etorqUll armnulo to lM

s pacllle(l lorque Hlting

Maintenance & servicing

1. 9

Every 3000 miles (5000 km) - ZR550 B & ZR750 C Every 4000 miles (6000 km) - ZR750 D 3 Spark plugsgap check and adjustment

~ ~

1 Make sure your spark plugsockel is the correct size before attempting 10 remove the plugs-asuitableone issupplied in the =~orcy
6.5 Pull the hoses or caps ofl Ihe vacuum take-of! stubs (A). The synchronisation screws (8) are in between e;'l(:h pair 01 camurettol'$ 2 To properly synchronise the carburetlOfS, you wi ll need some sort 01 vacuum gauge SQI-

up with It gauge lor each cylinder, or a manometa r, whtch Is a calibrated tube alT8rlgement Ihat utilises columns 01 mercury orsleeirodsto indiCQte engine vacuum. Note: DlJefothenaftireoflhesynchronlsalion procedure and the nfred for spei'system.

8 Air filter reservoirdrain ing (750 models) t The drain hose from the bottom of the air filler housing has a reservoir to store any oi l that drains from the housing . The reservoir is located at the back of the clutch cover 00 the right-haJld s;oe 01 the Bflglne. 2 Ult the rubber boot and check fofany oil in the r8servoir(see illustration). II any oil is present, remove the drain plug from the boltom of the reservoit"hos&aod aJlow the oil 10 drain inlo asuilable eOI"!!ainer (see illustration). Make Bur& the drain plug Is securety Installed 00 completion.

1. 12


'.4 R.....-the drain pIug..-d ..1ow the oil 1o 'hln compieMly IuoInglh R.fill ..thecr"'~IDlheproper""''' _ _ ", ~~

9 Engine · oiIcharlge

~ ~=:"t!kl:;::'}Ihe~='=':~ bel--' the high IIOdlowle>tel lines

on tile

A :~~~~::~;in~~:~·:::~1 ~~=;·J~~~~t!!:I: ...--bum.. "Hlfc.., e.u••

minnes (make ...... It'III1lhe oil pressureligh'

, ConaI. tM1"OUtirMoiIchanQe • • • the

singlemClOllimpo.'IInlmaint.,..,.,.~ youc;.,pIrtormon.moI~. Theoilnol

....",un::.*IheIntemalI*!.oIthe ....., ~_ct.IIc:h,btAft-.o_

• •

... ~all.... I.............~SIw.II~oII. wMa_"*>.Jtw, 1hent;:heo;ltIlwlDil ........ " -V.tdd_oIItobMglhe ..... up 10 the hlghtev.llloeonlheinsgeCtion wirI(Iow.Check ttla' thet..... noleaksfrom

=='..::-.:-..·-,-....-"-:,,------,

=:~:=~~:o:=~ r....

~ s.~ItI".IItf,.~onll'.

lemlle amount of abuse and should be

~------- CIleclru..oIdoll~-tf

~ •

1r1l¥..,._Ul/ic~,

I

'"...

'"• •

n,,""

II

.xperiencing ........ from (ne... .n,,"") or from In.uH/c/enl lublic.'kHI. II Ih. . . .re _~-In

1Iek•• orch;p.of mellllll ' h.oU.'h..,

,o"..,hln"

I.

drutlcally

...rong

/ntemIlIy_ t"."""",_,.....lobe ~forinspecUon_.....,..,.

"",.,.. _

pIecH 01 Iilw-.a ....M erog;n. (_lIIo4trallonJ • ~~" u n _ 1,,"- 011 drain plug tmm 1,,"oonomollhe . . . . . -.dlllawlheoiltollow inlOlhedraintray (_ Wlustnlllonj. DiIcerd the_ing w.1Mr on the dr'In plug ult replac;KI whene_!he plug It;

:::"be

5 When lhe 0/1 has comple!eIy dr.ined,

~I'

,

..

I ' ..

~

l P..-IodIcedjustmentoll,,"-clutchc.blell ~ to compen.." for,...., In 1""ciutd'I~ .. -.dstretc:holtIMc:KIN. N In tIMClulCI'I_gentlylO"llillhec:KINalaclc il laQnup, Itwn..-nlhegop,*-,1he "-, -.dbtacketClOmfl8'ing~wlthl""V ~!lon'l thebegjnr*lgollheCNpt.

(... iIIu.IratIonI .Hadjustmtnt"~.~

, ..... '

- ~'

~i 1\1- .

,-lNIingw",,*cw..-!hedrainplug.F~ t he

plug lotlleevrnpand llghlenKlo lhe torq",

~~i:, ~:.~ II1:1~:t~!)I.ng °1V: ~•.,., ,,=.,., ._ =H=.:-"'~.~'_ ~OO-:-'O-'_:ight..,lng••s damage to the wmp will

dnllnplug an;t=,:~theSPOCIfled

10.IM....uringclutch_1rHpWy


can be maoo al either In.e lever end Of the cable or at the clutch end. 2 Toadjust tn.efraepiayal lheleveJ, loosen the locking ring and tum th9adjusler In Of out until Ilia required 8mOUllt of Ireeplay is obtained (see illustration). To increase freeplay, turn the adjust&!' clockwise. To reduce I, eep lay, tum the adjuster anti. ck>ckwise. Tightelllhaiocklngrll'\Qsecure/y. 3 If aJl tl\eadju$lmea'(s •• ntustr.tlon •. Pullth. l.... er away trom the handjelw lW'Od turn 1headju$ler diIIl ,.n"lheset1ing which best ..... tslhe rider isoblained.Theno .... fourpos;lions.Alignlhe numbe< for th. """ing requ ired with the

, Eachbrakepadllas_rindicator.teps, CUH)uts or grooves that can be viewed with""t removinll the pads from thecBllper

1 A routJneoenerafcheck of the brake s)l$tern wift "".ure Ihat any probI9ms am discovered and remedied before the nd.r's safety ••

(seeilluslnrlions),Hthepads",.. womtoor beyondtneweey must be replaced, II the peds 8n'I dny or Wyou 8111 In doubt "" to

jeopardised

General checks

triangular matkon Ihe_bracket

the .mount of friction material remaining,

2 Check lhe brake_aod pedal for 100"" connections , im proper or 'OUllh action, . xcesslv.play. bends, and oth.rdamag •. Replace anydamalled parIS with new ones (SOOCllapt... 6) 3 Make sure a ll brake fasten .... are light. ChecI< the brake padstorwear(_Section 12) andmakeSU'e\hefluidlevo!lln lhereMe lronlbrake _ isdepressed.Thefrom brake Iigh1 switch is not adjus!able. II it failsto

operal.property, checki'(_Chapter8) 6 Make suretne brake lignt is activated alter

~'7o':~ t ~h~m,eo~r br~~!"";:~~~av~f::t~U~: adjuslment isnecessary,tIOIdlt!eswilchood tum theadju51ing nut on It!e swrtch bodyunlll


13.6 Rear brake fight s ....itch adjusier flul !arrowed)

Ih\I brake light is activated when require(l (see

Illu$lratlo nj .ll theswitchdoesn'!operateltl& brake light , check il (see Chapter 8).

13.78 Measorlng rear brake pedal height

the lQ(:knut secur&ly. Adjust the rear brake light swil ch atler adjusting the pe(lel height (seeSlep6j.

3 Point the front wheel st raIght-ahead and slowly move the handlebars from slde-Ioside. Ar1y dents or roughness in the bearing races will be fell and the bars will not mo~ smoolhlyandfreety. 4 Next , grasp tile fork sliders and try to move them forward and backward (see Illustration). Any looseness in thesleering

1 This motorcycle is equipped with taperedroller type sleering head bearings which can becoo>edented,rougllorioose during normal l.IS8 of tile machine. In exlTen>e cases, worn or loose steering head bearings can cause steering wobble - a condition that is polential lydangerovs.

movement 01 Ihe IOfks. If play is feH in the bearings, adJlJSt thflsteerlng head as fo/lows.

Brake pedal height 7 CIlect< the pOsilion Of the brake pedaL The distance from Ihe top of the brake pedal tip to the top of the rider's/oolrHt should be as speeified at the begiMfng of the CllaptM ($H lIfu stration). If the pedal height Is Incorrect, slacken theloer&aror by placing a support under l he engme.

IN ~ •

Fr"PIIIY;nth./orkdu.to

"'om fori< bushes Clln be misinterpretf}d for stHrlng h ~ad beerlng play - do not confutlelllerwo.

Adjustment 5 Remove Ihe fuel tank to avoid the possibi\jty o f damage shou ld a tool slip while

adjustment ill being made (..... Chapter 3). Slacken the steering stem bo4t. lhenslacken the loti< damp bolts On the bottom yo!<e (..... illustrationsl. Nole:DepM>dfrtgonrl!erooJs IWlJilable.irmay/;lenecessal)'rodisplM;eY>ll I!4ndlebIJm In order ro provkJe anoogh ~for8CCe appl;ed to the pek"pt cl .. anand

waylntotheareaswher.fr~ionoccurs . 1I

Tyreo 1 Check lhetyrecooditiooand tread deplh Ihoroughly · ..... DaiIy(pl-.-ricM)checI<s

o

t l>ebearing.lllathe adjUllternulbelow~

~

~ ==~I~.' ~:=~ a: er=c~~ 1r....

check&d pe.iodically lor cracks angused.applyil

~~~~:gt~ea:~n~~rs al~ra~:':i~(W:a~ ~~u~~ "",celefatad ra(8). NOle, OmJofllle/;lest

.\.lbrlc8nrs fortfleconrroiJeverpiolots is a dryfilm lubricant (1W1JiJabIe from many SOINCfU by

~~~=~·!ha cables.

disconnect th'

, elevanlca~eatjtsupperand.then"'bg.

1 Aemo1ffl the seal (S&f.I Chapter 7). :1 The electrolyte level Is visible through the translucent batt""Y case - it stlould be betweeo the UPPER and LOWER level marks. 3 II the &lectrolyte is low, remove the bettery (58ft Chapter 8). then remove the cell caps and fiNeach cell to the upper level marl
illU$tr8lion) ,Remove thecoverandwithdraw thefilterfromthahous~{see lliustrallons).

3 Tap the filter on a hard surlace 10 dislodge any dirt. SOak the element In II high flashpoint solvent until It Is clean, then if compressedairisevaileble,lIMtit 10 dry the element,directiog ttleair from Ihe Inside out {_ iU ustnolionJ.OItteowisedry~byshakirlQ

Ilorleaving~inlheopenairforawhile.

18.1 4c Shim H IK lion chart . ZA550·.xhaustva\ve$ 17 Instali ddislurbedCOO\lXll'1enlsfoi lowing

(see Chapter 2~

the reverw 01 the rernovalsequence. Apply a smearotsealanllolhecrankcase)oInlson the pulse generalor assembly covsr msting sl,lriace IIH lliustration).lnstali l hepl,Ilse geoerator assembly cover lISing a newgaskel and tighten Its bolts to I he torque ssttlng

16 Aotale the crankshaft S8'1eral tums 10 seal Ihenewshim(s).Ihef1f&oC11ecklheclearar>Ces.

Illustration),

15 lubricate the followe, with molybdenum disulptlidegreaseandinstaJIrtontothevalV{l , Repeatttleprocess foranyotherva/veswhk;h requiredattenlion.lhef1inslalilhecamshafls

spec~iedallhebeginningotlhiscnapter l_

.. . then in stall the cover using a new ga sket

21.3 Orytheelem8fltul~:ec:.:sedairdirectedfromthe 4 Chedde SAE30 oil . lhen wrap tt In aclaan rag and sq...eeze ~ as dryas po" ibte l.eelU ustratlon). lnsta ll thItftlteo-by ,eve<slng ttle , emovatproceduf&. Pres. the front of the elemenl again.llne

housing8Syoufittheco_toerlSer& rt leaves the

haodlebar {... Wlustration).Tum theadjuster unt il the specif~d amount 01 ""play Is obtair>edlsH n,jsChapter' sSpecificatioos). then ,etighten the iocImuL 5 11 th .. cable can't be adjusted to within

spe.;ifk:atlons, screw tne adluster all the way in,then remove Ihe fuel tank lor ace bottom 01 1M engine on
[)jO\CardIheMalingwasl1eeverlheplug la

5 When tha o~ has complelely drained, f~ a MW.esN"lIwashercwerll'ledrainpUg,Filll'le plug 10 IhfI SUlnfl snd Ilghlen It 10 lhe torqua

sett "'Q specilledallha beg inning 01 lhe Chapter t _ Illustration 9,5), Moid ~V:~ghl"" ing, as damage 10 Ihe sump will 6_ placell>ed r s"'lrsytlelow l h.oIl~~ ... , UnO\Cr(lwll>eoiffott ... CCVfJIboItanddroplhe IIIler assembly OUI 01 Iha en!llne ls e' IIfullrations ),TwiSl lhefillerOlJtolltsseat and off ~s boIl,ltIeo r""""", the wa.hItr ancI sptingt_ilklstrllllon).lf lhewasherlanol ontopollh.spting,il will besH>cklolhe !,.it'ide(sldaolltlefiItO)f.Mok..... e),oor(lIr\eVa It beloredi,carding lhe lilter. Withdraw the

' · 22


bOhfrorn \hecov.andcl>eclecondilionoi liS O·ring. AlSO check lhe cover O-rir.g, aod repl&C1O them II they are damaged or de\eriomU,d {SH illuslration).

~~~:-~:;.~::;=u:;,~~~ffti ~ , add""""oiIlobringthe _u p

to the high !eve! lIr.eon the inspeclion

1 1nstalllt!efilierboktllroughtll&coveraod

=~c:::"~,= thedt8inplvoandthe

the @erseal, then fitthesprlngar.dthe wa&heronto theboU, tl>eninstallthenew filt... uslng a twl$!lrtg motion, making sure th .. rubbe< gronvoo!s in l he filter remain in place (see Illu stration) . Inslall the liller as.emtlly

9 The old oil draioed from tr.e eogine cannot be ,,,-u5 mo!orcyc "'l>fIId "ertical,llleoil levelshould~

betwHn the upper aod lower marks (550 modeIs)orHBo'lClLIir.ea(750modeIsJontl\e i" spectlon window In Iheclulch cover """ Daily (pre -ride) clle(;ks). Install l he filler cap. Start the engine aod Ie1 rl run for two or It.""" mmtes lmak" . ",,, thai Ille oil pressure light

~onme.II the carburettor gaskets are leaking, the carbure\!o.s should be disassembled and rebuilt us ing new gaskets and seals (se8

Chapter 3).

Filter cleaning 4 Clean;ogor replac«nentof the fuel fil!eris advi sed after a particulsrty high mileagehss been covered. It is also necsssary if luel staIValionis8uSpected 5 Thelvel filltlO' is mount ed In the tank and is integralwtththelu~tap.Remov!ltherueitank

andlhe/uet tap (SH Chapter 3). Clean the gauze lilter 10 remove all \races of dirt and fue! sedil1'l8l1t. Check thfl gauze lor holes. If any

arefoulld,anewfitwshouldbefitled{check for(IVa ilabil i ty-~maybenecessarytorepiitCe

the wtlole tap). Check thecond~ionoflheO ring and replaceit il~ is in any way damaged or deteriorated.

'.23

tighten the bolts at the front and back 01 the

25 Cylinder head nuts -

~~~~~~750C)

~ ~~~~: ~he:~Y~i~~!~~I~~~ t~ :~: ~~i~~ ~

1 Kawasaki recommend that the cylinder head nuts are checked to ensure Ih ey are tighlenedto their correct 1000000eseltings , The engine must be completely cool 10rthAse mainlenance procedurltS,so let the machine srt ovemight before beginning. 2 Remove the valve COV8r (see Chapter 2) 3 On 550 models. the cylind er head is secu red by twelve 8 mm dom&
a reverse 01 their numerical sequence unti l they are aU slack. Using a torque wrendl. I'lOW tightenttledomednutseveniyandaliltleata time In numarical sequence to Ihatorque sattingspto(:ifledstthe beg inning of the Chapter. 'A'hen tl\e nuts are correctiy torqued.

25.3c Cylinder hesdtigtltening sequence- S50 models

torquesen ing 4 On 750 mOdels. the cylinder head is se
"""""'"

Ex/lMlstsjl!lemboltslnulS

Efl(JineoildrllinplugMldoilfi/terboit

===::boIf3

3 1f. tOtqUllwr...ch is .v al~" .(I$IIttalong

withthalOr'q.lespecilications.tthebegirw\ing

olthia,c
5 WiH>draw the &paeer. spring ... "t and the spring lrom the tube,nolin;t which way up they lit (see IIlustratJon . j. Compress the forks if necassary to 80CCess Iha components

6 Slowly iXl'-"ln the specified quantity of the spec~ied grade 01 Iort< oif and pump the fort
e top 01 ll>eforlc lulle

bonwlthlhefolfclube.Tltisls e polenti8lly

(see IMuSlfatioo). Scr9w II>e lop boll careMty intolhelO!le.r>d cl>&ck lor 1eaI
~;S;:::u~~,:.,~=~:;'~~ regul;JliQns-/oIUK~"'f...

roMOTT9S1

~""IIe1/$terenc.S.

1 The headlighl beam can adjusled twth horizorrtaIlyandV«licaUy.Be!Offtmakngany adjustment, check that tl>ltlyrl!l prMSUnlsare correclandlhe 5usp"nsk>n lsadJu$ledas required. Make any adjustments 10 Ihe headlight aim wllh the machlM On level QrOUnd. whn the fuel tank hall M ItIld wilt! an Dssistant slUing on tne seat. IIlhe bike Is

=~=:s~.:~~ the back. 2 HQOizontaladjuSlmenlismaCieby luming the adjuste< &c,ew In lhe,ighl ·hand side of the headlight rim (see IlIu , l ra lion j. Turn It

=!=~~,,%V~':~::'~I.and 3 Vertical adjustmenl is made by turnWIg the

adjuster SCrew in the basa Of the headlight (Me Illustrationj . Tum It ckx:kwlsa 10 move :::..~m up, and anti'ckx: l<wisa 10 move il

39 Engine- cyJinder compresskmcheck

~

~ ~

1 Amonij olh ... things poor ""glne p"rtormance may be caused by leaking valves. IncOITectvalve clearances. a leaking h.... d ijaskel. or worn pistons. rlnijs andlor cylinderwalls.Acylind ... compressioncl\eclc will hetpplnpolnl these conditions and can also indicate the preslKlCeol excessive carbon de!>s'1s'" lhecylinder heads 2 The only IOOS required ate a comp<ession gauge and a spark plug wrench. A compression gaugewilh a threadlldend for lhesparleck the 011 pre$Sure. a .... tablegauge and adapte, plec. (whlcn sc,.ws Into Ine cranl
58.000 to !;8.012 mrn 58.1 0rnrn

_Chapter '

2-2 Engine, clutch and tran smission ZR550 model. (continued) Camshafts Intakecamshattlobehelghl ..

E=~=~~

Joumalollcl&arance .. R""""qmax) ................ . Carnpress ..... pla.lebollS . . . .. .. . . .. . . . . . GealcltDr>geshaftco;ntraiisingspringlocalingpin Gealchar>ge mechanism boKs $t
Wear Umit (max) .

Cylindarcom.cression ..

66.005to66.017mm 66.10mm see Chapter 1

Pistons Piston d "meter (measured 5.0 mm up from skirt. at 90' to ~ston ~n ans) Standard. 65.951 to 65.966 mm Service r.mit (min) 0.03910 0.066 mrn Piston-to-bofeclearance +O. Smm

Piston rings ErJd gap~nstalled) Topnngand2rJdring.

0.70 mm (max)

Pislonringlhidmess

Tupling .. 2nd ring

0,970 to 0.990 mm 1.17010 1.190mm

0.90 mm (min) 1.10mm(min)

Engine, clutc h and tran smission 2- 5 ZR750 models (continued) Piston rings (continued) 1.12mrn (maxj 1.31 mm(max) 0.03010 0.070 mm 0.020 to OJ)6(l mm

0.17 mm (max) 0.16 mm (max)

Clutch Friction plate· Cl.C2 . C3 andC4 models

;:~~~s StaJldard .

2.6510 2.95 mm 2.5mm

Servicelim~(m in)

Warpage (max) .... .••. ...... Friction plate · C5 and 01 models

TypeApiale Quantity Thickne!lS. Warpage (max)

, notavaililble

.... .... . . . .• • ..

O.3mm

Type B plate o..antity . Thickness . Warpage (max)

5 not available 0.3mm

Pla;nplilte Quanlity Warpage (max) . . . . .. ...... ... • .. Springlreelenglh Standard Servicellmit(min) .

6 O.3mm

Transmission 2_550101 (27t23T x 631291) 2.600101(39/151) 2.333101(351151) 1.631101(31/191) 1.272101(281221) 1.040101 (261251) 0.875 101(211241)

Selector drum and forks 0.45 mm (max) 4.8 mm (min) 5.25 mm (max)

Seleclorforlr.· tollrOOV9Cleararoce. SelectorforkendlhickneSS 5electorforkgrOOVrbIlonIlY'I""which

0Nt-dr"i't .... d\llll· rctOf oil purnp,

...... ,,.. ,,"''~Nm

"NM "'NM

~...,,~.~~.~~~

~8 ...... bOM ... . ~rodcap...". ........ SeIectCf....."eam~DOk ..

NM

'2 Nm

Ca mahallcapDOks ..... Camahallaproclc8ltloU• . . C)'IkIOet *alhalhesragularandlreq.,enloiland _~IInCIClhwNqUAdfTllinteNra.

S-cAnchandldle(1l!W

wIII"-tlikely~manymilesol_

OI-..r¥1.oI,ou!¥1.oII " ,..,.,.lrIdoil

....-.Ic~

any major dlsmantliog ... orlg Inlo some

yourownbelor-e removingthearmsolhatit ~:~;::OICIIY aliyned wilh the s haft on

vttaIoomponeni.

11 RM"IoYe !he Iront sprockel COlI ... and the

3 Oralntlleengineoiland,Wrequlred,'emove the oil ~~er (see Chapt ... 1). .Remo.....theseata nd t hll~klepanels(see

Chllpter7). 5 OiscomecllhebllneryneoaliYe(-)tead{see Chapter 8). T.ace the blaclv'yelJow wI.e C
'" 8

OiscOfYleCt all lhesparkplug leads from the plugs and secure therrt clear 01 Ihe engine. "

the_.,enotllreadymarked , make.nole 01 thll cylinder number IOf each lead 9 OnUSmodels,rel9asethealrsuctlon ..~

2

=~.a=~ ~~ac:a~~ =St~-:n=

lIItached,notinglhe routingoieach_.

~ :"U;:~:':~e.J:=~:eI='~:'~:

=.w~:r:;:I!~":~=

Sh8ft, noting any Alignment marks (see illustration]. II no mari<s8fa ' isi b4e , ma ke

wimth9.«iofal/ea$ton..ssIstant;peISOfIIJI itfutYordamagecou/doccurif!heang/N~ orlsdto{)ptKJ.Ah~ormach6nicaJfIoor

iaclsho<Jld be UHd 10 support andlo_or raise !he engine IfpossJbla.

Removal 1 PO$ition Ih_ bike on ii, centre stand or support~securely i nanuprighlposl1lonusinQ

anauxl~1II)' 5tand.Workcanbttm8 """""N!r

by.llisirlg tile maehirle 10 a suttable working height on a hydraulic .amp or- a suitable IlIItionn. 2lfthe&n\llne lsdirty,perticuiarty ...oo.n::Ilts mounlings,washttlhorouojllybelorestarting

.. and lhest.ane. motOf

to_cover

5.14 Pull back the rubber co ..... r and disconnact 1he staect

theoilprasl\n.wIteh~tromtheswitcn

Dn th. IfI1t·hlrHlllda 01 th.sump IH' lIIustratlonl

!::~~! t~::'7n~crd~n~ki:'c; : eonr.aclor(a) I' " lIIuatrl Uonl. A-'lNtse lhe wirirlglromaroydiplOf tlaI,noting~.routing AIso~theliOMtMd_cn...rt'lgat

Iha conneclo< IOd pul l the neutral switch 'NiringtInt"s .Wg bolts. lhen wilhd" w Ihe boil. {_ " lust'ltion) .R..movellletJolts MCl.ringtheriQhl-hand "'.... enginemountir>g bracke1IQ the Iramealldremove the bracke\, notingoow~lits ( _ iII ust ratl ons)

23 Thot6nQOnecanoowbe r~tromthe

"""",, . cn.cktnataflwrng,cablnandhosM are well clear, then m.anoeuvr.lheeng-.eout ol theJight-handakleofthefnlme 24 Cheek the condition of the tfont mounling bracl<et rubbero:!ampersand'eplace them If they are damaged or deteriorated. Lubricate ::t,:::~withasoapysolutiontOaid

5..22c Rea. mounting brac ket bolts (arrowed) - 750 models

~ ::.:;:~ "" llIe e"**"...-""the~

__ /inkagDarmendshall when insraRing It>e ..... ""tothashall,and tighlenlhe

pinchbolrsec~.

h) Mal<esurelNw;-. cabOes IIIdhoses are cooecrlyroutedltndconnecred.1ItId SBCIJredby""YcIip$ or 1Hos. J) Ra(df ll!eeng;n..wilholl(_ChaptlNlj. DAdiuStll!edrivechaiflf~(see Chaptar l~

j:)AdjusltllethmIfiftCilbh! freepllty,!he cJrJrcl! freeplayand rile Idle $peed (see ChaplIN I~

-m.led - parts together (Including gears.

~~::sh!:=~="e,~~!:~a=

during engine operation). n-a "matec"' parts """"be reousedor replacadas an ass-embly. 6 Eng lfle/transml.!lon disassembly should be done in tl>e foliowinQ g...-al order with """""",,atolMepproprial.es.ctloos ~tI!e..w...CO¥er"

Ramo",tl!ecamc1Wr>lfINiot'rertmdeM71

=='IIS

Remove !he cy1inderhead Remavetl!ecy/inderbJocll Remowltl!epi!ltOll3

Removerr../gIIifiotlfOlorendpoJlse

="',:::cIu~(seeChepter.fJ

Installation :l5 Installallon i, the "verse 01

~cr~ca,:*,~sothattheenglnerests"" 5 When disassemblin-g the e ngine, keep

rernov~l,

ootingthe lollowingpoints .., Mai<eS8WOIle must be used . Uslnga flal-bladed screwdrivar, turn Ihe slotted end of the lensione' clockwise 10 release Ihe lens iooaod allow the p/uoger 10 ,et,acl lnlO the tens ione< body. RemoV1! Ir.e screwdriver and cheCk lhat the lensioner;::M'-""Qe< springs back out 01 the I _ b o d y 6 Ifthelens l0lle1Is, you m"s' .. move Ih.

--

.

9.26UIl.c' .... the c.pboll.ndwilhd'.... Ihespring and . toppe'

dldl'lO t,~ease

24 Apply . smearol _ lantto IheCfaIlkcase joims on tM """seg""""'loressamblyccvar malingsunace(SM ltlustf8t1onj. lnstalilhe l"'iso!generatorassamblyc"".usingaMw gasket and lighlen lis bolts to tile spec,f,ed IOfQUese1tir>g (see Ifluslr.tlon). II removed. inslall IhtI VaMtcov. (see Section 8).

:

t. n.ion",..lIt,.. .... y . nd .." tll

~fo ..

tig/!teningt.... boIts.T1Ie I... sIor!eo'eXfands IfseJftlfldlocksklpl-.so /fyooloosetIt/le boItspslfw"ay8t>dthenrellglllen t........ u.. terISiotJegspecitiedal lhebeginningol \he Chapter. 33 Place a new oaslr.et on the lension« body, lhen mlaillhe tensioner. making sun the IorIgerboltitinslall&d uppennost and with It$ aluminium washef (see illustrat ion). Tigh ten the mount ir>g bolts gradually and evenly to the torque seu ing specilied at the beginning 01 the Ctlapte< 34 Install the slopperInto the lensionerwil h ~s taperedfllCeup. making sure II lils agalnsl the tapered faee of the plunger (see lfIustration 0.26). Tha end of tha stopper should protl\lde about 10 mm from the tensioner. If the stopper sUeks out too far the tenslontlasnotbeen\.akenupbythe~.

Iftl-is is theease, remDYfI the pul$egenerator anembly cover and tum the crankshaft eIoekwiHueingal1nvnsocketonthetiming rotor hex (_ III... tration 11.2a and bl.

Caullotl: 00 NOT use the liming rotor bolt 10 tum the r;renlrshah . it may snap fN s trlp out. AJsobe SIlre to tum tM engine In fts fIOfTMJ dNection of rotation. Set 1herotorSOthalIheTmar1gspecilledat lhebeginnir>g 01 lheChapler 1& On 750 mode ls. if ,emoved, inslatl Ihe pivoIs/'laftintolhebiadesolhallhenalendS I_up. Fit lhe rubberdampersw~hthe UP

::! f~.:,:::~r:.."!i::.t =:lIa~eS:a~: crankcases",~ra!9d.T1>etensi<JecylinOerbk>ck( ..... Seclion I5)

::;::~lpioandseparatelhebtadeandlhe

::nsg an auxiliary s tand so thai lhe ,ea, wIIeef is otl lheg ,ound.then s eleClahlghgea'and rolsle the ,ea r wheel by hand In Its normal

10.16 F\tlhetenslonerbladelntolhe crankcassu .... own

11.28 Theputsa generalorassembfycover IS S&Curedby IWObolls (arro,vg.d)

~~ac~~ S;n~O~~!d "o:=~~del:~'~I~I:~

Cam chain guide blade

~ =:~:Ol~ha: 1~S;tS;,t: ::~ chain lunMI in Ihe cytinde,block,noting which way round R frts and how~ locates. Inspe(:tion

8 E.amIoe lhe Sliding surlace 01 ll>eguide lor signs 01 wea' or damage. and ,epiace II it ~....,.

Installation II InSlall the blade Into IheI'onl01 Ihecam chain.......-.et in ll>ecylinderblociEX_ 9 PuilthissidedthecIWI

Engine, clutch and transmission 2- 19

11:'~~I;~;:=~ng I III/merle

2 Sprocke/OOt/s (1ntalle}

~~~flopnx;l!et 5 :'-mntcmmMflsprocJcet

~~~(exlwJsl) 9 PvIIlhissk/8ofl/lac/laln

and 2•. II in.~~u,at.

~

doesn·t. the valve timing wI~ be and the valves will ~onta~1 the

pistons when the engine ka I\.med
1 Rllmvelhecarbumttors(seeCNpl... 3).

plainw a SherS and I W'08mmbo~s.wtt<ehare

l"'!AI -, ~ "'0 ' _-= -,1-. . 1< ~7--= . _

.

~

~ ~- ~. ~t.-o ·ecytindlr,andlnlakeorexhausl v_l

:~.labeIedplaslk:bllgswlldojust

e HnoI-..ctydone,cINn"lracesolo/Cl ~akl' materW trom,he cylinder hIIad. II . scraper is used. tal<e c"" not to scralch or gouge the soli .Iumlnium. G,skll removlng soIvenlS, wTIictl work-..ry well.•",.vailable I t most motorcycle . hop. and lulo pans • tOf". Ca.elully ac.ape all c.'bondepose pllCktrMIcamlllaring

""rtaCHforw"'lnd,vklen,:aolseizu". Cl>eck the c.mshalt. and 1oI1ow.... lQ<w,,, • • Mllt_Sectlonll). 12 U,lngl preel. !Qn s tralght·edge and a leeIer ~Ml to\hewarpaoelimil~$tlldin

Ihe epecllk:81Ion• • ttllebeginningollhe Chapt •• chec:k thllhndgasketmating ...-fee. lor warpage. R.!.. 10 Tools and WOlflsl>op~inlheR".. ence$OClionlor dll.11I of how to chIlClS$i\'"

;t=.,;:r:.

":"'oo:.alain1he c:ombustion chamIIIIr.1I1hIy.,pIt1l1d,rnckedor bumed.

::::~~"~he~a~.!

widlh aod compare h to this Chapt.'. SpecIIicationl t_ilhr.tretion).II~uceeo:II

theMf'ikllirM,orllhv"-""""""ib clrcumf.ence.velvlovertlllulisrecp.rired.H IVIiIabIe.UHl'ruuianbluelOdelermirletIM e>ctent 01 v...... _ _ . Uri!onnIyCOllttIM . .e t with th.Pruulln bl .... then Install \he v.!v.and'otalalt back and lonh using I l.pplngtooLR_.lh.va!veandchack -..vhet har\heriogoiblue onthev~ lsuni lorm

end oontinuou. . .O\>'Id

theva~e.

and 0 1 the

CClflWlwidth .. 1P'dfiId I. ell.n the varv. guides 10 . emove any carbon build·up. lhen mllaU tile valv. itt II. g .... 10 th.t III lac. iI 10 mm.bov. the _t.Mount.dialgeu(leljpin$tthllsideat tt. ........... ~IO_cylinder_su11C11 ..possibIeltld_theemountoiside cI...ItIC.(wobbIe)lIIIt_thevllve.t..... ltIdillguidtlintwopeto. arourld Its clrg and uC,,"5lve waar. Tha presence of any 01 the above conditions indicatMIhIII.......:jfofva/Veservicing

17 UslngV· bIocksand a dial oauge.me8SUre tha va lva stem runout and complre the

w.... raoo pitti r>g. Measure the s pnng I'M length and compare it tolhat IIsta
;~::S=~=!": i= il:~

specifocalions (SH lnustrallon).lfenyspring is sIIotte< than s p6(:llled It hn sagged and must be replaced. Als o place the s prir>g upright on allal surface and check ~lorberld

specnied. lhe va/Ve"..".t be replaced

18 Chllckthaandolaa
to tile vatv.laca. then sHp'lIe vatv. Into .... guide t... I"...t ..tion). NOli: Mak.wnt..,;h ........ lolm/lJIfed inilscomlCI guldelndblCflrefu/"""OI1$'",,ygr!nding compour>donllllvlWIstem 23 Attedcoi~laciOlgdown "'tothe cyliriderhead.l~by t hespring r e\alnef.

wi1t1~. INII"" sooulde<ed side wt>ich Iii' into the top 01 ll>e springs lacing down . aodwith t l>eshimCU1-01lacingup l_illustra~ons)

28 Apply a s mall amount 01 grease to the collets 10 help 11010 them in place as tne pressure I. ,e1l1ased Irom the spring. (sell illuslralion) .Compo'ess thllspo'ingswilhlhe valve spring compressor and instaUtl>e coIle1s (see IlIuslrallon 14.Sb). When compo'esslng tt>espnngs ,dllp,esslhemonlya. !arasis absolute!y neeessary to slip the collels into place, Make Cllrlaln thai Ihe Coliei . 8'11 securelylocklldin tt>eirre!aininggrDOVilS. 29 Supporlthe cylinoerhNd on blockS SO the valv8S can'l C()r1lact It>e workbench to!). U>env""YlI""tly tap""cho!lhevaIVII.lems with a soft-!aced hammer. This will help seat Ihecol\e1slntr.e;rgrooves

t4.27c Makll sure the spring .."ain.... ls

14.28 A small dab 01 gnNIse will help to ke&p the collets in place on the va .... whil.

thecomtClwayround

the spring Is rllleasfld

15 Cylinderblock -remOllal. mspectionai'ldinstallatioo NOIII: 11N!cyMdMbIocIecarnchain up and lift the cylinder bk>ck up toremoVII it Irom thestud s, lhen pass the carncMin down thn.logh the tunr>e!. Dc nollet the chain lall Into thectankc8S\l' secure rtwrtha piecll olw~e ()( ""'talbarto pr<WfIecylirSS/Ve,Sllf!k lheadvlce ofabikeenglnoorlngspecialist

B iJ!.ingtlliescopinggaugesandarnicrometer (s " Too/sand Woflrs/>op Tips),checkth
'.

.

"

"

.

0

fiI~

15.3 Remov. ,eeh oil nozzle _ its O-ring O-ring nor nllerJ ro 750C51J1ldDlmodtIIs

2

2- 26 Engine, clutch and transmission

15.8 Mea"""" lhecyllndeemsecure!y

Installation 15 Check that Ihematlng surfaces 01 the cylinder block and crankcase are I,ee Irom oM or pIec:"" 01 old gasl<et. 18 Remove lhe'''IIS Irom arounc:l 11>& pistons. and lay the new base gasket In plac, on the crankcase making sure all the holes ara corregnedand thai lhecut-oul in one end 01 the gasket is on the le\I·hand sKle of theengine(550modeIsJ 4su litus lrallonJ or lhe UP letters on t he gasket lac, up (750 model. ). Never ,e' use the old gasket Note, Tile gsskel malerialon 750CI toC4 models W8Scllenped from paper-basfJd10 aiumirUum,lIworlringononeoflllesetn(1o)/S, :=""'U,el~8 I tnaaIUmjn/UmgaSkeljS

17 MakeStntl>&oiInozzIasareclMn...-.dnot

4 O-ring'

~550i'50~'C4 bIocked,ihenlnslai themntOtheirholesintl>& crankcase making Sure they a,e the cor' ect way up (s ... illustration), On all 550 mod~s ~50~:;~odels,m a new a-ring 18 1Irequired,ir1Slali pistonrtngclamp$onlo

:::\~s=;o",e=~:::~ ~~'Yfsln~ll::~: as each cylinder has a good lead-in enabling thepistoo rlngs tobehand_fed lntolhebo
15.20 Pass ll>ecamchalnUlllhroughlhebkx:k

16Pist~n$-removal , inspectiOf1 and tnstallatton

~ ~

Note: TIlecrankcase \JSea$harpscribeo< I9Itmarlcerpenlowril.

:,:::,:':;rc~::::' t~':~=

'=

pislonpm-lhiswiNtrapthecirclipifit springs out.

=;::e=~~::::E:'= ~=======::;

have an arrow marked on it.e,own which shouId lacelorwards (' HlllustraUonI6.3b) If this is not viaible, marl< the piSIOn aeeord ing~ so th at it can be insta lled Ih" COI1'ecfwayround .

.,.--oo..

..........-...""..,..,."..,n'nc."'~ ...

t I"" clrcIip on one $Ide ot

' - _ - ' -_

_

~_-'------J

2-28 Engine, clutch and transmission

16.5 R_oving ~~~=u:;;:~ganng....."oval and

must bttused. When the piston has been removed. irls(all ~s ~n back inlO rts bore so

:1 ~:~:,::ss::Ot~: ~m= ~~~::a:: (lbtained

for eadl piston

Inspection 4 Belor .. Ih .. inspection proces, can be carried out. the pislonsmuSlbedeanedand the old pislon rings r«nOVed. No(e (ha(ifthe cyIindets we being rebored,pislon inspection

can beovllrlookedas","woneawlllbefJfled 5 Using your Ihumbs or a piston ring removal and InSlaliation 1001. c arefulty r&mOva Iha rings from (he pistons (SH Illustratlonl. Do rIOI rkkorgoogethepi51onsintheprocesS Carefulty note in which groove each ~ng !lt . as Ihey must be ins talilld in thair original positions If being re-used. The (OP nng Is ..........arI<ec:landcanbelnslalled .. thMw~up.

:""m~SU:i~:I:::":~~!: n~ 550 moOets ,the ring Is Identified by tl>e I&tter

T. ar>d on 750 models bylhelellee

finglands. Normal plSlon wear appears a s eYen . vert ical waar 00 the tllrust sur1!>C8S 01 thepislon and slight loosenesa of the top ring In ~s groove. Illhe skirt is scored or scuffed. Iha engine may have been suffering from overtleating and/or abnormal combus tion. wIlichcauslld excessively high opera!ir>g temperature s . The oil pump should be checked thoroughty. Also check that the c r~ip{Tooves8f8ooto:lamag!ld.

to A hole irI tile piston crOWrl. lItIe>on Oepo s ~, . Dooot ,emove any melal ar>d do not nick or googethesidHof theringgrooves. 8 Once the deposits hava been removlId. clean tile pistons with sotveot8nd dl)' them tho,oughty. If (he iden t ~lcation p'eYiou.ly

_

....._-,,--,..,..._

IgjJ 16.13S1lpthepln(A)lntothepiston(B) I ndtrytorockltbKk ..""orIh.II~' s Iooee, replacethe ptstonlndpin


Installation 15 Inspect and inSllll1the piston nng s ,s"" Sectiontl) 16 Lubflcate the piaton pin. the piston pin bore and th .. conoecting rod smal'·end bore wilh cle8n engine oil 17 Install a newclrcllp IrI one side Of the pi.tonldc not re-u ... oidcirclip. ) I..... 1I1 .... l ra llon).Uneupthepistononllscorrecl connecting rod. makW>g suret1le IWTOW 00 t1le pis ton crown laces forwards , and insert the pistonpif1lfomlheothefside l_'ft",tmtlon 16.3b). Secure t,.,." pin with the other new circ ~ p . 'Nhen instal!lng the cIrc~ps. compress It1&m onty jl.l!lt enough tofil them In ItJepiston, and mak.. sun, they a, .. ptoperly s aat&d in

~:';.!o~~e~;;;~~ the

0p&I'\

end away from

17 Piston rings·

inspection and InstaHalion

2 layout lhepisloos andltJenewrir>gaetsllO ItJeringswlllbeln8!ctledwilhlhesamePS100 andcy1ir1d«duringlheand gepmeasur«nent procedurearldengneassembly 3 To measura ItJe end I/&P. insert ItJe tDf' Mq irltothebo!tomolthe forstcyiir.dera.nd$QU8fa it up wilh l he cylinde< wa lls by pus hIng it in wilhthetopol,hepistoo.Theringsllouldbe c\OQ!o thabollomadgaof thacylirld .... To meaw .. the eoo gap, s lip a feelerga<Jge between 1M ends ofltJe rinq and comparelhe m.. a5llr.. menl to th .. sp ee ~iealioos at th .. beginning 01the Chapt... lsee WIU5lrallon) 4"thegap ia largerorsmal l... thanspecified doubIecl>eck 10 make ""'.. thaI you have the correct~nos before proceeding 5 II the I/&P is 100 SINIIt, ~ musl be enlarged Or the ring end s ln8y come in contactw~h each oth ... during engineop&
theringanymor.. thanisnecessalY

17.IIC compre;::;:';:I~ro5S'Mreunle ... being replaced t_ IOustraUon 18.13)

18.3.8 Clulch cover bolts Isrrowedl-550 models. Note II>e pos.itions of II>e wiring clamps IA)

550~ . t hep1 .... lhe lrictionptatesmvst be ,&pfac«l as a set AI.o. if an~ of the plates sme41 burnt 0' a.e gtazed.thflymust bolr8pl3Cear'ng. ... lea ....od afldth ..... t washer (750 mode4s) lor signs 01 roughness. w ..... or damage. arw:l ... place any parts necessary. On 550 rnodeI$. thl! Ml/)ase bearing ffts into a oousing ln1t>epresso.weptatel_IRus lratlon)

a.

' 4ChecIeshaft~sealsI>owssignsolleakage.orn

the shaft bear'rngs ieels rough. w~hd ,a w t he lever and shall lrom the cover and reptacelhe bearings aod .eal. Not.: Removal of tile re/$8$e shafl from tfle cover INiII damage tfle oil...,.l - always mak.. Sure t~a 0;/ seal;s

~j:::e~:=i~~8~

::::. the shall.... taII ~ 110 that the punch mark on the shah aHgns with the mark on the lever as shown l_ iIIust.ations). Apply grease to the oi1 seal lips AAd clean engine 041 lolhe shaft andbeatinOS·

Installation

~~a':::""'::I~~~c::!~=!rom 1t>e 16 Sljde the Inner tlvust washer. wiitl its llat surlacetaciogOUI . on10lheeod 01 tht mput stlaft l_ lllustratlon).

Igine, clutch and transmission 2- 33

2 17 Lublical l>Qu, ing, s tarting with afric:tion pt.te, then a ptaln plate and attectorlromthefl"archanll"mechanism

~

Or'um. ar'ld whk:h hole in the drum the longer

:s~~ ~~;'~~I::a=n~:I:":\~~~

neutral light will not worI< correctly . Take care not to lose MI'I of the pins.

isCrTeCt1y

~~: ~=::c=~t~t:::

Inspection

release \eVflr and the adjusl ... inlo lhebracket on theciutchcova' tsee IIIu5tralions 19.1g andll.Attachlheuppe<endoftheir1nafcable to the clutch Ie .... , ll>enalign lhe.kll.inthe adjust .... aodloIadown ;nloposil;on. Using Ihls melhod will ..,sufWlhacabia is routedcorrectly. 3 Install the cable. making sura

c,ankcaseWtheyare k>ose • Note r.ow the gearchange shalt centralising spring ends f~ on each llideol the k>cating pin Inthec'ankca .... andl>owth .. '8Ieclora'm and stopper arm engag.e with the pins In \he

20.3 The g ..... cf>llnge mecf>llnism cover Issecuredby .. vensc.ews(~modeI,) or bolts [750 models)

6 Inspect the ,haft centralising spring lor laligue. wea , or damage. II any I. lound . II muSI be replaced. Alto chack that the spring locating pin in IhecfMkcasais secu'ely tlghteneose. rernove ilandapp/ya l\OI1.permanenlthreadloongtMlsMfl

:;!:bd/

"-.....

13 Srartef"durct> 16Spting

'7~/Iub

18Demperrubbers 19PrimarycMin

--

20BeatinrJsIIMMt 21 Sheflnul

"

23D1tr7¥*'ISaImOIy

dlfIctI.W/lhthelh8flremoved.o:bengagethe _WlCI'I~fromthepr1marychan

arrlcate lhe i d l "'.edUClion~ar ' ha!t

wilh clean eng ine Oil, then instal l th .. idl"'reducHon gea' followed by lis s haft, making Su,e the sma ll", pinion on Ih .. Id l eiredUCllongearlac"the~-hand side of

fMengine. Secu.e lhe shalt with theE-clip

:aF~;·U:h':':'u!:·~~sher

Into the s tarte, ciutch.l.ubricate thehubofthest""",driIfen ~arwithcleanengineoil.theninstat l the

start", d'riven Ollar into fhe clulcn. rotating it anti-clocl<w ise as yO<J do solo .preadlhe roIIer1. aod ajlow the Ilub 01 the gear to em ... On 750 moOeIs. lubricate the needle bearing

3 Unscrew the bofts securing each oil COOler

22 Oil sump and o il pressure regu lator-removal,

inspection and installation

~ =ar";;7~od~n~! ~e~.::~..:,~!~a: ~

Note: Tt!e oil sump andprfI.sufe reguleror canberomovedwirhlfleengineinlfle~.

If work is being carriedou l wilhlhe engine

remoWJdignorfllhepre/iminalysreps.

R emova l 1 Rernovett>eexhaostsyslem(seeChapter3) 2 Dralntt>eengine oil(seeChaptert)

used. On 550 modet. \excep! the B4 modet). disconnecttheoilpressure s w;tchwiringffom thesw~chon the left-hand s!de of the sump (seeillustralton) 4 Unsc.ew the sump boHs. $Iackening them ""enlyinacriss·crosssequencetopre.eni dislortion .Aem,wethesumpand ll' gaskel ~!,::::i::)~!SCardlhegaskel8$a 511 required. unsCrew the oil pres""r..

;~:!~::t:':~~=~~~lelt_hand endolthesecondary . haft. Manoeu"'ethe starterclutcn assembiy into lheaanl& righl·hand side of the c rankcase aod $Iide it ttvough the . tart", ctutch assembiy and Into lhe bearing" the lelt · hand slOe (... Illustration) . Tap the ,lghl·handerW 01 the sIIaft with .. hammer unlil the right-hand bearing is fully seatoo In

:~ ~~hkac~se~~t~::~ria': :"v:eil~:~ ptacetJetweenll>esllaftandthebearing fs "

~S;~::)nulontolheleft_handandOllhe . haft and , u.ing the method employfld on rernoval topreventthe&llahlurning. lighlen the nut 10 tM lorque setting specified at the beginning of theChaplef f_~lustralton)

23 Install the remaining component. in a fI.\lerseOfOOr of removal. Use a new O-ring on the shaft bearing cap and smear it with gre ...... and on 750 mOdels. make sure the wiring clamps are fitted w;th the setews

. . .""--_-"-~. . . . 22.4 Unscrew the bolts and remove the sump

Engine. clutch and transmission 2- 41

' lPIIOlator t,om tl>e lump and remove lllullraUOII)

~ l . .e

a Remove I II !races o! 11"51e""""";..om /hi

"""""'''ff>lTramt."wot1r~''''''''''c.m.d oulwllh'heeogineTfHl'lOWKI~'he

Re mo".1

j AerT'IO'o'e'hlcMcI>{seeSactionIB). 2 AernovfIthloilaump{seeSaction22). 3 The oil pump Is SlCured by a DOlI and twnshslts

or components are mad" as though the engiflft t~ the correct wily up. Theret"'" the rl9h1-hIInd end of. shafF or s~ of. CtlItlkcIsewilfactull/ybeon"/O<Jf"'''Mj'OII i0oi< down onto the undersidfl of ths CtaIIir"""".SSIImbty.

Separation 1 To lCCess the cran1<shafl. comec!ing rods. beatings and Iransmission componeo\,. Ille a ..... cage must be SPIiI inlo lwo paris. 2 TO eoable the a8l1kcesesto be seperatoo. Ihe engine musl be remoWld lrom Ihe Irame I_ Section5j.Belomlllecrankcasescanboo sepw8too.lhecemchain tensloner.camshaI!s. cylinder Mad. cylinderb(ock. Ignition puise

a Turn Ihe engine upelde down so Ihat it rests onthecyt;nderheed,tudsaod thebeciw."crankcasll boItsasahownl_lllusntlon). 6Wo~ l nglna r_r. . ollh"ligh"n"'g sequence Shown lsee illustration 2a.5}. slae upper hal!. using eilhllr a 60ft hammer 10 lap ......-.c! Ihttjoint or a $Cr1IWdIiver inserted into one 01 the leverage poInrs cast Into tha crankcase. to in~ially separate the halves il neces5al)'(_Hluatnotion). Thereare th ... leveraQe poInl,., one on eiltler sk!e 01 the

MsiJyv.:&edtlfldwillMkoil.Useorlytile lWO ~poinls. Thelcwerc""'kcaseha~wiO comeaw~_IheMlet>«ffng

rod

~~intended.lul0::fs8ssemblvoflhe top-end~nec:essa")'.

3 Unscrew the thlneen 6 mm upp." crankcase bolls illustration). Note: As

'SM

24.7 Use a screwdrive< In one of \h6 leventgoe points 10 sepamle ItIe Cl8nkcase halve$

24.8 Re move the two dowels (arrowed) il they are loose

2

2- 44 Engine, clutch and transmission

.J " •

-

L.i

, ~/ t l

... ; ,-- "'VI,I,I

. "'

,,

any Ilgns of undlle stl!!ness, tighl or'oogh spoil. or ofanyOthe< probItrn, the 1l1\li1 musr ~reo;tAIed~~Iwther,

22 .... talalOIhIr~-..oIieIinlhe r-.eol theseQUenCegt.enIn$lep2

I

25 Crankcase · inspection and S&rVicillg

I.

1 """Ihe~hlW~~ed. rIInWYe the a"rilhafl, bNrings , oil presaure Iwotch and t,ansmlnlon components . .. lerringto t.... 'elevant ktions01 thl.

:U.t2aen.roullylubrk:.t.lhecranlulhaft m.... bhrtng.

lIEnsu,.thatllllcomponentlllndtheir

a.,...-.:IIoChapt.elortlleoil~

bearings"'elnplaceintheupperllndaow..

SWiIch, If~,"""""'lheoiljetslromlhe

crankcase hat.". Check Ihat the t,anW>isslonbaarinOlocatlngplns.ndhall_ ringret..,.,. ...... correctfylocated.• nd

pas,age adjeClnl 10 the middl,

b~.end

_"II cut-otJI " "" I.om Ilia transmission oo.rIptII Shall righi-hand beMingCUlooOlll In!he eower Ctankc... hall. NOlt thai the iet adjac"'t to th'bIog_end bearing i. Slaked in piac:e and could 8ully ~ dam.oed. --.tIlling fIII)Ieoemenl 1_ ~""lnItionj.

Ihet~heoilJ-IS.ndlheru_oiIp&ss;Ioe

pIug.,tlle lransmissioninpu1shall rlghl-hand ~."ng(uPPtrC'at\I«:."hall)h.vebeen InIuIed.M~.

12 Generoutly lubricate thtt tranlmission .tillIS, selector drum and 'orlcl, and Ihe crat\I<sIlaIl,~r1iculatfy"OUndthebearingS.

AJIMJ"""""IhefUbberoilf)llsM{IIplugift Ihtt l.ansm inloninpul lIlalt nvht.har'ld

IOithdean"""""'oi.tMnUMlrag.atlkedin hoghnaatl·PQlntsolY""towipeOWfthe

100M (......IrMion).

~arlngifttheUpperCrankcaseh.llltltis

~kelsu1lCMoIbothhelvesto.amove,,"

trac.sofoll l... lliustrationi. 13 In.tall the 1Wi) Iocaling dow.c, In the uppercrarol«:asehalf l... llustratlon:UJlj. MakeSlnlhattheg.earMlectordn,mllinlhe neutralpoaitlon. 14 AppIyllINIIamounlofsu/lableMllant (KIIwasaki-8ondi2104-0(J2orIlQUivllenI)Io

~~loc.oteODmor;tlylnto""'lowa" 18 Checklhat lhttlowerc,"nkcasehalf II

correctly_ted. Nole: Thf!CtMlrcBsehllNa

~lIfion:DoIlOlIlpply"''''~.",.,..nt

rhouIdfltlOfletl- wfJt>outbektglotcM.lf1he cmvs_""'COt>"KtlySllolJted. IWnO'te file KJwercflln.\"cue l'IaIIand/rlw,lIga lall'le ptObIem.DoIlOI.rtempltOpulill>tmtogerhet

hIIINs_~_"""_'tVCtoil jYuagea. Do not . pply Ih. . . . on or Ioc>close lo . nyoftl'l.oiIPIIlsege .. __

Ireoly and Ino:Iependently In neul .... Due 10 thcl

tMmatroglUrlacesoithttcraokc_1IaIvR .. v.own (_

lIlul lnltlon).

o I ' - " . I f _ _ out..tten''''UM

,."t

bNrlng~orbNrlng

::=~~boInUfileCollsing'ril 11 Checlww

crankc,," bolts 8nd Insen lhtm in thM

originaIloc:llioos(see Noleabovel.s.c...-eah boI!smge._light Ilfir11. thentigtll", the bolt, llittIe.,.Iimt..-.:lin""'~MQL.W1OI

-'>own to the torque Hlting specified at the beginning 01 II>eCh,pI.. (s. . Illustr.tlon .

24.51.

18 Cleatllhe thlNd' of Ihe .... en 8 nun ......... etanI!oaMboItJIlInd __ lhemin!heO' or1glnallocaliom lIIu.,.. Uon24.5). T~ht""alitneboItSl l i\tJ""I t1m.toth. apecjfiedtorquesenlng. 2Or......,lhttngiot_,1nsIaI1he1toirt-.8 mm upper c.ankc.... boll. (... 1f"'. t ..lIon 24.3). Toghten ajl the bo/Is a lillie al a time to lheapeoifiedltwqllllMftOng 21 Wrth"cr_c_r,st"".,.tlg/'ltened. Chttckth.tlhecranklhaltandtran.misslon

I'"

_. ,

:M.tS Frtlheto-",,"downontothe

shaflsrot'''lmOOIhly9o'ld~1y.~lher.are

2 The c,ankcues should ~ cleaned thoroughly with newsoivent and dried wilh comprQ"" .... All oil palNg" and oil )eta :s/"oouId~bIowncutwilh~ ... 3 AJI_oIoidgasket8Mlantshould~

.emoVed f,om tM mating llUr1acQ. Minor damege to thtt W,fa
-....

engine_ ... ottenptaWrt.Atnsi¥a ... IOfMII..-teft In engl ... ,tte. 'KOnCIIIlonIngopetllions.especIallywtlen

""""""*'''

~O:".,::.:..~~~t~::::

1OUf~1. lhese lor.ign objects oft"" end up ImbeddIdIn 11'11 lOtI bea+.g mat....... _ ... 1 ..IIy'KognIMd. 18'ge particles ... 111 nol rnt:Ied In lhe bearing and 'Nitl score or gouge lhe bearlng_JoumIi. Th8 besl pt1lventlon Iortto.o;euseofbtiri'"lglaib"elstoclNnlll perts thoroughly Ind 1gs in bolh crankcase

011 clearance check 12 Whe lher new bearing shalls are baing fillad or tha orig inal ones are being ,e-usad. the ma in bearing oil clearance should be Chacked belore the eng;ne is "",,,,,,,,,,bled

and dry. Lay the cranksha!t in posiIoo" the uppercrankcase tseellluslratlon27.3j t BCW ......... allenglhsol theappropriatesize Plastl,.au,.e (they should be slightly shorter than!hewidtnofillacrank$haltioume/).Ptace a s lrand 01 Pla.tig auge on each (cleartedj

:~~:~~~: !~~:;~~on). Make sura the

Eng ine, clutch and transmission 2- 47

17 Carefully install the lower crankcase hal! on to the upper half. Make sure Ihat the selector forks ~f fined} engage with their respective slots in the transmission gears as the hal~es are joined. Check that the lowe.crankcase half iscon"&ctly seated . Note: Do nof tigllten tile crankcase boIrs If tile caslng is nor correctly seared, Install the lower cr&nkcase8mmbolts (see illustration24.5) In their orig inal locat ions and tighten them a litl leat a timeintheseq~ceshownlothe

torque setting specilied at the beginning of theChapte< . Make sure that thecrankshatt is 001 rotated as the botts are tightened.

18 Slacken each bolt in re~erse sequence starling at number t o and WOtking backwards to number I , Slackeneachbolt alillieata time unli l they aIe all finge9Cllng nxf smalHtnd and check for l ~aybetweenlhetwo (_ III U 5tratlon)

7 Aele< 10 Secllon 26 end exemlne Ihe con necting nxf bearingsh&fls. II they a ' e scored. badly scuffed or appear 10 have S&iz1Kl. new shell. musl be ",slalied , Alws\'S

r"eplacelhesheflsin!heconneclingrodsasa se!. 11 Ihe, a'a badly damaged, checklhe corr$SpOl"ldingaankpin. EviOooceofe.treme heat.sU(:hasdlscolorBtion,"'dicatllSlhat lubr;caHonlallu'ehaso<xumxl. Se . u,e to thoroughly chec~ lhe oil pump and po"9S$u,," r"9ufalor as well 118 all 011 holes and passagea belore..."ssembIing!heengir.e

B earing Insp e c tion

she ll select/on

connecling rod size mark (eithefe Oo,no mark) is marked around the waee0l'l« again (the new sl*lsmay be thick enough to bce timit listed in this Chapt er's Specilications, measure the diameter of l he crankpln lournal with . m icrometer and compa!'e you, find ings with this Chapt er's SpecificatioM . Also, by measuring the d iameter at a number of points aroond the joornal'5 circumference. you' ll be able to
making",", ~ 1oca18$ correclty in the grOOYe inlt>eshafl lseelltustratJonsj 19 $11(1ethe2ndgearpinionontotheshafl. lotIowe
bearing with lhecin::lip, making sure ~ local.. correctly In the groove. lnen lit the bearing

QUlerraee (seelnustratlons) . 20 Check that att components have been eo:wr.cltynstalled.


3O.1 ge . . . ttlen slidetheouterrace oyerth-ebeari ng

30.21 Sill-speed transmlsslonou\put shaft componentl I Csgedballb&8ring 2 Ciulputsh8ft 3 Sleelballs 4 2ndgearpinlon 5 Splinedwasher 6 Circlip 76/hgearpinlon 8 Circlip 9Splinedwasher 104/hgearpinion 1I4lhand3rdgear

.." 123rdgflSl"pinJon

13 Spfinedwesher 140tr;1ip 1551hg&8,pinion 161S/fl"","pinion 17 ThIck Ihrusl washer"

18

Needle~ring

19 Circ/ip

Output snatt disassembly 21 Remove the needle bearing outer race from tM right-hand end of the shaft, then remove the circlip and slide the needle bearing. the thick Ihrust washer and the 1st ge3rpinionolftheshaltlsee lllustnl!ion). 22 To remove the 51h gear pinion il is n&setheballs

~

20=~ L -_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ __ _

27 OIJring reassembly, applymotybdenurn paste or engine oil to the matingsurlaees of theshaft,plnionsandbllSh.lnstal1lhebush withitsoifh~ealignedwllhthehol einthe

30.22 Hold the OUtj)ut shaft as shown and spin It hard to release the 5th gear pln loo

shaft. When instaWng the circlips. do not expand the eetplinewa1het. followed bylhe 4"'and3rdgearbo.lVoingonlolheshah.!hen slide lhe 4th !I"' pinion and Ihe3rd 11"3' pillion onto the bI"hing, followed by the solillll walMeholes withtha iltustration).

drilling •• ftarthaballhas~in$ta lled ,

..... ow.. outsk\tlcHamflt. i_

noIuaagrauauthebalilwil.ticktoorro..ch

Plllioniinthe~torforkgorODV") I'"

To . toptham from contlllUOUSly rolling out,

illustratlonl.FitQMottllepositivellllUl.al

squirtaomedNnengl .... gjllntoaachoitha

and the neutrlll Iystem wiI notWDllC8olvapou r lromthesa

Air .. drawn into the carbu"ettors via an air which Is housed under the IlJflI tank Theexhaust syatElmonSSOmodels " aona piece lour-into-one de",gn, Bndon 750 modeI•• lhreepieceloor·inlo-lwo ~tt8t"

Br!":~~=ed~o:~:mm=:~::

and lor that reason areincluOed In Chap\&r 1.

""""""'aodmove w"lIclearbetore~.

Check a11.....,tricalequipment belonging to thehou!le,gara(l'Jorwon<st>opwhereworkl' beirlg o.ndertakan (see the Salety Io,ti sect\on 01 Ihls manua~. Remember Ihat certain el"" tricalap~ i Bncessuchas drill s.cutters

e lc . creataspa"'" In the normBI coorse 01 operatIon ar"ldmvst nolbe used neBr petrol

(gasolina) 0< any componen t conta ining It Allain, rernembar lhe possibie Pf" ""nce ot fumes betore using elactficaj aquipment Alwaya mop up any spilt lue l and sately dispose ol the rag used Any s tored tUe1 thBt is d ralrntd off during sarvlclng work must be kept In saaled coot.aio:len that are $Uitable lor holding petrol (ga""lIf1t1),andde arlymarkedao.uch: th" contalners themse1vas sl>ould be kepi ina s a'e place. Note that this last poOiseorolpoflutants. In practice, this mean. that adjustments may not be made to any pari 01 the fuel. ignition or exhaust systems by anyone who is oot authorisod or mechanicallyqualiliad to 00 so. Of whodoas oot have the tool!l. !IQIIipmanI

Fuel and exhaust systems 3 ' 3

and data necessary to properly cany out tha task. Also if ar1y part of these systems is to be raplaced~mustbereptacedwithonlygenulne

Kawasaki components or by components wh ich are approved under the relevant legislatkln. The machine must neverba used w ith any part of these systems removed, modffied fit damaged.

2 Fuel tank and fuel tap removal and installation

*

Ll..l

lose the mounting rubb
6 Inspect the tank mounting rubbers for signs of damage or detarioratOofl end replace them il necessary. Also IrlSp8CI the rubbers on the fuel tank mounting bracket . If necessary.

":

~ =a~~t~ehV:~:~=n =f:~:r::~ ~ ~ =:ho~ :/:~~,e:I=~:~:::~~~

:,:,;:~r,~ns ;/:~: In ;:ct/o~h~ ber.".. Sllutlng

2 Remove the seal and the side panels (see Chapter 7), then d isconnealfirst. 3 U'lSCr(lw the bo~s securing the reat of the tank 10 the tank bracket on Ihe frame (see 1IIIISlration). 4 Draw lhe tank back sli gh~yand raise It up althe rear, then release the clamps securing thefuet hose and thfl vacuum hose to thfl lap

"""*.

Fuel tank Removal 1 Make sure the fuel tap Is tumed to the ON pos~ion and the fuel cap is secure.

sensor overflow drain hose and disconnect the Sef1!1Of wiring at tha connector (see Illustrations). On California models, detach tha EVAP system hoses. Plug the fuel return hose (red) to prevent fuellicwing into the canister. Label the hoses to prevent conluslon on installation. 5 Remove the tank by ca refully drawing it back and away from the bike. Take care not to

.. . and disconnect the senSOr wiring

3-4 Fuel and exhaust systems

-.

..-..awwtt-.twobabMCUringthebrad<et to thel...... tnd'emov.thebrackelt_ ~Iu.tr.llonl . R~_ the rubbotnr if

7 II 'IImOV..:j . Inlt lll the tank mounting btacl11 ,emoved un.....:H..'lly d .... to the possibility 01 damaging UM O-ring or the filler. and the tap sho<JICInotbldl!lm.nUed. 13 Removethe!ueltriasdascl1bedaboYa Connaet .drllnholfl tO lhe ' ualhoseunion and InMrt ~alnd In. container $UiIabIa tnd largeenougtllorllomg1hepetroltgasolirlej

12 Th.

TumthefulltaptothePRIposition._attaw

the""'" In .. poeiIIotII..lhw! blow

~

Ihrougn

thel-*lo~d!1Iin.

withCOfl"ljlr-..dIlir.

14

1& II the IuaI tap il Ittaking, Ughten!ng the ....-nbIy _ _ on t... tronttndt.lkoithe

~thetwobolt . MCUringthetapto

the lritnd withdrew the tap assembly 1_ lIIus, ... Uonl).ChecIs.lnorderloc:omply with the regulation., the carbureu ()r$ on US modsIs.ssealsdlOlt1eyc:an1be\ampered with. The pilot .erew. on other models are accessible. but the UH 01 an exhausl gas an;oIyserislheonlyflCCUnlt.waytoildjust!he

.... - . .

IIbIetoproper1ytldjust!heidlefueLlairmixlure to lIChleve a smooth Idle and restore low

5 CarblJrettor overhaul general information

lOI\Ient and dry them with liltered. I.mlubrlc:etad compressed air. BlOW through the fuel and upassages with c:ompresaedair tolorce out any dirt thai may hay. been looaened butnol removed by l ha solvent. Once the cleaning proc.ss is complete, reassernbHI the carbureltor using new gaskets andO-rings. eelor. disassembling lhe carbureltor., make sure you have a carbure1tor rabulld kit (which will Include all necessary O-!inOS and other perts), some carbure1tor citenlll, a tupptyolcleanrags,$OmI!I..--.solblowWlg out the carburetlor passages and a clean place to worir.. tlis recommended that only one C8lbureUor be overhauled ata time 10 a'lOidrroixingupparts.

e

-

1 Poo. engine perlormance, hf!sitatlon. hard starting. slaliing. flooding and bllC~liring are all slgnl th81 major carburetlor maintenance maybe required. 2 1<eep In mind thet many IO-called carbu.euor problems are really not carburenorproblernsatall,bulmechenlc&l probIemawilhin Ihe engine or Ignition system maIIunc1iona. Try 10 establish lor certloin thai thtcarburetlecarburettor healer syslem wiring eonneclo.

6.6a Siacken each clamp screw larrowed) to rele"e the earburetlon . .

3 Remove The screw securing the raar section

Nole: KHP thj ewtJuretfOt'S uptight to pI&VIfII

oftheairfiUerhou~ngtotl\efrootsaction.

fuelspiMag&lromthefloatchambersandln.

IheOllittthe ... IIIICtionOUl I _ inustTa tion).po$$ibilityofthepislood~belng • Slide back lhespmg bandssecurlnglhear damaged. filter housing n,obber$ to the carbureITor 1 Detach the throttle eables from the "'takes 1_ Illust.al lon). ManoelMe the ar earburettkllyus;,g._Q-mp$ (seeSI8pIOl,~anon-pernl&'l8ll1

tf1tewjloclOngootTf'OUlldlOlllabolt

eJ

1Iresds.",;J/istlf1W1lOlhespedfiedkltQlJe. Maka.$l.¥1lrflfltIKfiJI(If'l'Iou$/ng'andllla eyfinderheMiinla/la~rtn_fuIIy ~wilh/hae8/tltJ"'tr0t'5andtheir

relain/nf/$prlngsoreJampsare$6CUll!

7 Carburettors - disassembly, cleaniog and inspection

~ ~

.&. ~;:~~:~~:;:'n i:efJo~h~

d}MllkaSlJlllllllho$flsareeorreerfyroo!ed

Disassembly

ar>dseeurad, 8IIdno//rappedorkinkftd. a) On UK ZR550 94, 95 ar>d B6 models ar>d UK ZR75() Cl, C4, CS and DI models, do notforgel/ocoooect/hae.tfOOmtlor heal6l"" wirinQeonnee/Ol""s f)Chackrflflopenlllortoflllaehokeand

t Remove 11'08 eai"bIJfSllors 1fom the mactlW1s as dascrlbed In ths pravlous Section. Note: Donot sepIUII lalhacarburellOf"Sun/as.s lllisis absoIvl~~;eacheatbumfflYcanbe

dismantled suffleJenlty ftx all normal eJaaning

llIIaInk!gllCf8WS (see illustr8tion).L.JttoHlha

::.:':=::.~=-=!;

come out with 11'08 spring - if not, itwilcome out withltlejal needle (Slep 4). 3 CtveIuIy peel tha diaptngm awav from ha seelinggroovelnltlecart:uetlorandwittldr\lw thadiaptllagm and pislon assembly. noting whicI'Iwayround~ms ( _ illus t ... tlon) . Caullon:Donoluse llsha",lnslru~I'o

dlspillea Iha diaphragm as It Is eBllty damaged. 4 PU$h lila jet needle up from the bollomof lila piston and withdraw it Irom 11'08 lop Ina Illuatrlltlon). Take care nol to lose \ha apring

rhronlec:ableslllldadjuslrhamss necessary(WaChlplerI).

separslelyloaWJkilnlarellangingparts, or

elM slora tha parts from aach in marlt,y will be enlarved, cauosing 'he fuel and air ""'~nt'"tobelJPM'·

Inspection 17 Ch«;ktheOl*'8tionofthecholle ~ . II ~ doesf1't move smoothly, inspect \he neMlle on tkeendollhechokeplunger,thesprifl{j arid the plunge. linkage ba •. Repjaceany component that is worn, damaged or bent. 18 II removed f.om thecarbu.ettor, check the lapered ponlon 01 the pilot sc.ew and the spring arid O_ring for wear Of damage. Replacethem~necessary.

19 Check tha carbu.eUor body, float chamber and top cover for cracks, distorted Maling.urlaces arid ot'-damage . II any defecta .... found, replace the faulty component, although replacement of the enti... earbu-ettorwiUprobilblybenecessary

Icheck w ith a Kawasaki dealer on th' avallabllily of separate componenlS). 20 Cheek the piston diaph.agmfo. spli". hoIea andgeoeral deterioration. Hokflng it up ~,~I~ht will help to .eveal problems of this 21 lnHf1thllpistoninthecarburetlorbody arid cheek thaI" moves up -and-down smoothly, ChedIthe surlaceof Ihepislonlor wear. If lfs worn excessM!ty OIl doesf1't move ltr'IOOIhIyinthegl.ide,rupIaoe\hecornpcnen\S

u_.

U CtwtckthejetneMlleiorstraightroesaby •Qlling iI on a flat surface such as. t)ieC. 01 glass. Replace It II it's bent or If Iha tip Is

-.

23 CheeklhetlpoftheHoalneedltvalveand thevalve.seal.l f eilhe.hasg'oovtsor scratches In iI, oris ln anyway worn, they mllstbereplacadasaset. :M Operat, the th.ollle shaft to makesu •• thtlthr01tlebutleOlyvaiveopenaarldcloaas .moothly. lfildoE!sn'\,cleaninglhetlvoutt linkage may hetp. Otherwise , .eplace the earburfJUOII. 25 Check the floats for damage. Thla will usually be apperent by the presence o f luel Inside one of the floats. If the f1a.ts a.a damaged, they must be replaced.

8 C8rburettorsseparation and joining

Clea ning Caution: Usa only a petroleum based $OIv""tforCllrtwreUorc/ealling. Don'tu.se CIIusUCclell...... 14 Submerge the metal components in the soIvenlfor.pproxlmatelythirtymiout8$lor longer, if the directions.ecommend 11). 15 AII8f c.rbu.attor has soaked tong

Separation I The Carburettors do 00\ need 10 be' separaledlor normal 0IIIII'tIauI.lI)'OUneMIto

tn.

enougIIlor\he~tolooeenanddissolve

mos1ofthevamishandotherdeposits.,usea

7,16 Do notlorge1 the air p.assagea In the IntakH larrowed)

separal.ltlemlto.epIoce acart:....ettorbody. fOIl example). reler to the loHowing proc«Iura.

3

3- 10 Fuel and exhaust systems

Joining 7 Assembfy1$ the raverse01 the disassembfy procedure . oo~ng t helo/lowing. a,lMak.. surelhefvelIloseT·pi«esand joIn/tIgpipesandtheairvenllloseT· piec$SIIf8COffl1CtJyandS8ClJf8lyinslaJl«;l wilhfHIwO-tings. b)lnslaJIlhesynclltonisationsptings.fler Ihecmt>umtlQr"!lllf8jo1n«ilogetl>er.Make sure Iheyllf8 COfflICIIy and squarely _ted 1_IUIISfnofJorr8.4j.

cjAppJyatlUitabierKlfl-pemlai'Hml1hreltdloc~ingcompoundtolhe~/tOf" bnK:~"lsc""""and lighl9()them ~..,.

dlChec/rtheopet1ltionofbolhthechol«l andthtolflelinlC l<ets (, " iflYSlraliona). Th carb-u ret\o,," a re assembled using a

:~a~:~~:m~~~~t;=ay

make

6 Car"'ufly s.. pa,ate the carb-ur"Uor' RetrievethesynclYonisalionspringsaodoote thefittingollh e .ar i ou s ju ~ ho$&T · piec .. s

..)lnslaillhecart>uteIIQr"!l(seeSection6)1HId ClleCkCWOU""/Oi"synehrortisalionand kJleSpH<J(seeChaplerl).

9

~~~~~~at hei g htand ~

lue) (eve! check

A

~

~~;=~: In ;:CflO~h~

ReesHmbly a nd float he ight che ck Nole:WhenftNJSS«nbJir>glhecmt>umIlQr"!l,brt su",lo II.... 811 fHIW o-ring$ and 0NIs. Do not

overtighl/ffllhecmt>um/tOf";elSandscrawsas

lheyareea.silydamaged l ln slall t hecl>ol<e~ andspringint otM

ca,bu'6t1or body and I;ghten tl>e nut to

••• andlhelowe rmounlingbracke l ac, _s t8lTOw.dj

(600typelhown)

Fuel and exhaust systems 3- 11

.. Q'~-'

-,

~".'. - - -::: ~',

.1

9.la Fit the Ino&rplasticwashet"5 . .

9.lb . . . andthellnkagebar •.

.. . makingsureltlocal as correclly ooto each plunger

9.ld Inslall Ihe scr ews wlth the outer plastic washers

secure it. Install the choke linkage bar inner plastic washers. then fit the bar onto the plungers. making su re the slots tocate

9.4b . . . theneeclIIl Jetholder ..

correctly bahindthe nipple on the end 01 each chokeplullgf!( tsee lllustrationsj.lnstalithe oulerplasticwashersandsecurethet inkage

9.5 •• . andthemainjet

bar in place with the screws tsee illustralionj . Hook the return spring to the vacuum takEt-otl adapter, then lit the cap tSH IIluslratlonj. 2 tnalal l the pilot acrew (il removed) along with its spring, washer and O-ring, turning it In until il seats lightly (see Illu stralion 7.11j Now, tum the screw out the number 01 tums previously recorded. or (1$ specilled at Ihe beginnirIQoltheC!lapter. 3 Inslalithep;lot jet (SHillustretiooj. 4 II removed. lit the ne9dle jet inlO the carburettorwilh lIS tapered (smaller) end lirsl (se-elllusirallon). Screw the needle jet holder IIlI0 thecarbure1tor ts.ee iliustrationj 5 tnstall lhe main jet inlothe needlflj!l' holder t_ iIlustratloo). 6 Hookthelloalneedlevalveontothetabon the Hoat assembly, then position IhellOOI aS$&lT1b1y In thecarburetlor and install the pin. making sureil is secure (see iIIuslratioos) 7 To check thelloat height, hold the carburenorso IheRoat hangs down. lhenlilt II back unlil lhe needlflva1ve is just sealOO. but not so lar th.at the needle's spring-loaded tip iscompressedan t onthap/lton

!aclngtheWltaka.~ftheeart>uM\tOf (_

-.

cartIo.ntt.,..(rwllngon.boK,!ore~).

Corw>ac1.hosetromlhefuellllplOlhe!uel Inle' lilting on ItIII carourattor essamblymak .... ra IlMluei t.p ia In tIM ON or RES

O.ll ln.talltlMdlephragm.,...,..blywlth

thelndenl ln=~!'!:.facl"'the air Ihownlnltlaoccornpanylngilustration. Hthe Klwl ..k1 I00tilbeingusad.'II,.tl>ezaro rnIr1urattOfmalnbod)'. HI ~of_pll..tict.-.g is bein9uHCt.

........ rnIr1urattOf1lt-Section6j.

O.tIIFuelle""lmeasu"""'"'t

I FuellaveIgwge O.12 fnttalf thetopcOVlt.maklng ..... the ...,tngitoCOlTlCtlylocatedtopendboltom

~~:mwt

S=bodr 4 Beiowercable nipple with mulllpurpose grea.e Bnd atlBch it to the choke linkage bar on the cBrtlurettor llee IIIU$ll"ation 11.2b) . Frtthfl ovt... cablelntott. bracke1 lseeillustnotionll .23)

11.8 Chenl·-"""'' Ookot, t..,.".oc/\ P""in""'cytindt< _' O _

......_l.

~_ 'opoll.,.ctoni«:aM..,.,

~

c

, Unoet.w ..... '-_-.c.~

-nv.Hk>t.rotlonl. Al,.., till ...,.. 1,,,,,, , oIeU8 till ...,,*_,,, H_dbolt,thenre4eaMthesilencerlrom the .. hausl downplpo U$&mbiy usfn(l a

assembty."'-'O.'-~Mg~requQd,

twistingmoliot1 (_"lust'Cification. at u.. begftlingol1l-..ChIopt•. I To cneck lhecondition oi the secondary winding •. HI lIMo mel ... 10 tlMo K ohm scale. 1.kIIctaw11Mo'f*!CplU\jcapsf,omltleendsof 1I-..HTIead. !aH U'uatratlon).Conne'Cled rHutt. """a)'O\H findingsconfin'nedonthediagoostictHI ... !_Stllf)'). It tlMocoit is conformed to be

Installation 11 11\aIallllionialhll""""",olremove!. InstaN lhe coils wilh the HTlead. taclng IotwItd.MaIewiringCOt"neClor.8lO'ontherotorhe~

10counter-hoIdh.llndlll'llCfeWlhebo/l.,lhe c.1t.. of lherotorwtlk:hsecllfft ~ 10 ItIe lind 01 the C•• nkah.h (.... mutl ... llon). Remov.

4.10 CountIf-hoIdlheoutlfhe. on the rotor andunec.--1hecentr._

Iflstallation ll l1 removeetoo" OI)'MgO' ....

Hle;>olQrOloonoonlrcl uniI

!.~~' :h::::~ ':t':-;.,~';e:.~ :aiI~ ~~_ l"". ''''~IO'

lgmlrllF~eigo'\_1I>e

Check

It8t1c1ln'i1gmerlt. 1nc:,UUllMfilginespeecj whil.1 observing lhetlmlng merIeighl 01 IhtI Hlver ,elal;ve to Installation 10 lnslallalionis the ' lIIIerseolr.ooval.AJlgn the marlc . made on the gearchange lever 1ink&gelltmandshaltwhen inSlalhnglhearrn onlO the shafl,and lighlen the pinch boll secureJy {seallluSlratlon).AdiuSlthegea, leverheigl11 as required byslackenirlg the rod 1ocknulSafldscrewiogiherodinotoulrnihe IlIIIer afld linkaoe a rm Isea lIIu 5l,allon) TIghlen lhtliockflulssecurelyonoompielion

4 Stands removal and installation

sidestandandunhooklhecanlreSland spting, Ihflnunscr6wll>enuIs,wilhdraw lhe boilS and remove the Siand l_lIluslr8Uon) 2 Ins.pecl ll>estand and piv1 bolt. for signs 01 wear and raplacetliem ~ necessary. Apply

a smear olgreasa 10 the boilS and filthe stand back on the bOke. tightenirlg the bo~s sacutely. Reconnecl lht1re1umspr;ng. 3 Make Sura the spting Isir1 good condition and capable of holding 100 Sland up when nol in usa. A bfoken ot Wilak spring is an obvious »felyhalard

Sidestand • Thesidesland i.allachedtoabfacketon

::;:""7ha~I:~:~ ~o~~e~: ote.'endedposi'ion 5 Supportlhtl bOke on~.c""tre. tand il lified otsuppor\ ~usingan auxiliary stand BUnhookthtlslandsptingafldunscrewlhe

~ ~~Eet~~:~~~:~~:..a~~~~~t~! " '0.,"""' ..".",.""",,,,",,,,,, bolt shank and lighten the bolt securely.

Centre stand (750 mOlhJ/s only}

1 The centrastaod is secUfed in II>e Ira"", by two pivot bolts. Support the bike on II.

Aeconneclthe sldesland spring and check that lhe relum spring hoIdsll>estandsecur9ly upwh" nnolinus"-anaccie displacfHi lor ecCflSS to the forIc top bolls or rll$stHrlngsr""'lWlwirflour removing rll$ switchllousingsandtll$lront b..-aksmast...cylinder assembly Bnd the clutCh lever

...semboY. 1 RIImOIIe ItMI screws securing both the Ieftand right-hand switch housings to the hand lebar. noti ng how lhe top mating surfaces 01 the switch housingsaiign with IhtI top mating .urfaces of too brake master cyl lnderandclutchHlvar .. sem~yclamps then separate the sw~ch halves. Detach the throttle cables !,om the throttle pulley and nolellow IhtI ct>oke lev... m. l..... Chapt... 3 if MQuired),thenremov" thehousings lromll>e

Frame, suspension and f jnal drive 5- 5

handiebar,llOtinghowtheyfit(seeChapt9t8 if'eQu i'ed). The'e is no need todisconned ~:,itChhoU SingWir!ngalltsconnector

2 Disconnect the bfakelight switch w iring comeclors from the underside of the master cylinder. Unscrew the two clamp bo lts s~u'i ng Ih.e front brake mast o!!" cylinder assembly to Ih.e hand lebar and lilt the assembly away (see Ctlapter 6 iI.equ ired). There is no need to disconl">GCt th.e hose irom the master cylinder. SllPflOrt the assembly in an upright poSition and so that no strain is plac«lonthetlose. 3 Disconnect tile clutch sw itch connector from the underside of the \ever bracket (see illustration) . Un screw th e two c lamp bolts s~uring the clutch le~er assembly to the handlebar and lift Iheassembly away. " Unscrew the bolts 8eCuri ng the hand lebsr clamp and remove the c lamp lop and tha handlebars (see illustraUon) . Note the punctl mark on the back of the hand lebar which aligns wi th the rear mating surfaces of the clamp. Remove the clamp bott oms. not ing wtIich way round they fit ar"ld how they locate (see illustration). 5 If neces.sary. unscrew the hand labar endweight retaining screws, than remove the weights Irom the en d 01 thahand leb ars.11 replacing the grips,it may be necessary to slit themuslngasharpkn~easlheyareadhered

to the thro\!!e twist (right-hand) and tha handlebilrQeIt·hand)

InSla llalion 6 Instattation is thereverM 01.8fTIOvsl. noting the following. a)AJ;gntheh8nd~sothatthepunch

msr1rontherearoflhehandlebarlfiigns with the rearmsling surf~es of the clamp {see lllustratJon}. Tlghlanthelronl handlebarclampboits to the loltju. setting specifiedllt the beginning of the Chapter,lhflfltighlentherearboitstolhe

specifiedtorqull.TIleres/lol.Jldbeligap between tlleresrclamp mslingsurfaces b) Makesure the frontbrakenuv;tercylinder clllmpia inatalledwith the UPmar1r fllcjng uP. 8!>dso that the top clamp ma ting surfaces aJign with the top mating surfsces of the switch housings (a. . illustration}. Tl(}htenfheupperclamp boIIfirst,thenthelowerbo/l,rothe tOn:jtJlJSlJttingspecified llttheOeginning oftheChilpler. Thera should be a gap befWetH1 the Iowsrclampmating wrfaces. c}/fremovad,applyawitablenonpennanantthreaeJ-loeI\lelorlc legs ha'ffl been dismanlled or if Ihe lork 011 has l)een changed. Ihe lork 101' bolls shooId now be lighlened tothe specified torque ""Wng. Nowtigh1en Ihe fork clamp bo~s In Ihe lop yoke 10 IhfI specl!ied torq"" !HIning.lnstall lhflhandleba .. Hd~aced

7 For1l.s -disassembly, inspection and reassembly

Disassembly l A1ways(ljsmantlethelork~ s separaletyto

avoid interchanging parts and thus causing an

Frame, suspension and final drive 5-7 bolt. slacken ttle axle nu t clamp bolt in the bas& Of the fork slid&r and rE!OlOVe the axI& nut (see iUustJellon 6.8). Compress Ihe fork tube in the Slid&r so that the spring exerts maximum pressure on the damper rod head, then have an assistanl slacken Ihedamper rod bott in ttle base 01 ttle fork slider. 3 II the lork topbott was not slackened with the lorkin sku. carefully clamp the fork lube in e vice, talting carto not to overtighten fYSCfYem

dry wilh comPfessed air. Havallabfe. Check the fork lube for score marks . scratch ....

~~:.t=t::.7.!==~ replace II\e tube n both Wany ar.loond. fotl(s

Checl< thetorkseaf!;OOlfornlcl<s.gougesand scralches. II damage Is evident. leal<s will 15 Checl
Frame, suspension and final drive 5-9

install the boitinto the bottom 0 1 the . lid8f (... II1I1. tra Uon) . Hghl .... Ihe boll 10 lhe .peciliedtOf"ueae1tlng. llthedamperrod rotates inside tM tube. tempoed IlIlIy into Ihe s lider so that any =~~I;~~inO Is confined 10 the area 22 When the bush is sealed tully and 5qll8telyinilsreoes.n lheslider,(fflInOV8the washerIOcheck.wlpelherecessCIean.lhen reinstall the washerj. install the new 0enli1ther>ewO-tlng ( _ NI... tr. Uon 8.8b) . lnstIUthebelringcoYer 1fIdlllreadlhe.cllullerrlng.wlthllsstepped sidelac:irogdowrl.lIrldkld
ng''''''

5

5- 12 Frame, suspension and final drive

8 F~II-.'-~buringonlOt".,at-'"9 stem,Allngtholtublng-...ith.nlnt...... , lllightly Ilrger than Iheste«Wlg stem will be .-ded to tap th. new bearing Inlo posltk>f1C... lllu. t,.lIon).Ensur. th.tllle d"ftbe",onlyontlle'nneredgloltlle

,.eer.wbolt~IIOt/lttln.g

II--.g lIem bodc i. ,_ed. but "so making ....... thallhe~oIlh1rnactoin11isotflhe rearsuspenslonsoth.,thl ,holbNrlr>g

2 On 550 modejl, .. mo .... the .~haust ,y.",m. and on 1SO model •• remove tile lilllrlg. tu/tabllbe.nngdrlverorlltnglholPiIM iNI'-'on/yagMmlhen-race.nd noIapIns1lhe~or"-sl'

DrlCk .., (s. . Iliullritionl). When 'emovl ng 1IIe"ght·hand Shock. counler·hold tile bol!

rnounlingbflckllonlhe...w.o-m. .. Supporlingthlthockablorblosition 2 is thesl andard setting fora ridar 01 average build. riding solo.

5

5- 14 Frame, suspension and final drive

Compre••lon damping . CompressiondampO'lgadjuslmenllsmadt b)lIunWlglNlodjuIllronlhelopollhe.noek IbsorI>tor 4_ lnul 'r.'ionl .There"",fou, poIl,klnl.PoIUlonl,, 'he soltes'setllng. pos;,ion. ,nemwdes1. 5 T"mlheltdl"S1.,..unlillhflnumberfeQUlred .'igmwlln ll11lnde~mark on the sllock. 00 nol "' IIII~J "II"' i nl>lllw""" anyof lhe poeiI~.Poeillonllsll-.."andatraQ light lwi1ch.pnng...cfposiliontl>esptingoutol 5 Suppoo1ing lhel.,..;"ga,m.f8fIlO¥'IIlhe.Ihock IbsorI>tor 10_ mounlinv bollll 4_ s.ecI< lorplay ln ll>ebearir!gl.

_

,"e

~:nc::'::h t:~~~:Yma~~v:it~

........

wllMtandlhockabsorbefllnplltc'l_ Chapter 'I .... hIOhlighted wI.h tlllM

7 Remove1helw'ngarmllldCJlPI1_ ..... UlItIonl ·~lhenutonlhelet't""'"'-"d enctottl>eawingarrnpivotbolt.• rldon7SO modIts......,....thewashlr l_illuslrltUon). Wilhtlll iidol anas'iSlanl10,uppot11ne I wlngatm If ,equi,ed. drittthe pivot bOtl out and wi1hdt"aw ~ Imm the fighHun:l ,kit oI lne "' ame l_ '~uttr.tkN1I.No t .thepoaItionIof

IIIlytwaalh1r...cfdrainpipeaanc:lmove lnem aakHt II nac....ry. th"" manoeuvt"a ,''' IwlngannOUlo!lhIl>ackoilhamachint. thecond~ion of tne cMin llidtron

8 CtIao;Ic

INfronIotlha.~.oortplaceMH~1t

womordlmaged l_iluaUlltionl.

7 TumINadjusllrW11i11he.......-.blrflql.ked Is..,.,,....cf ~tlckllntO position. 00 lne adjuster In bet_any 01 lhe positions. PotiIionlltlheltandardsetting

not'"

12 Swingarm · rllmovalandil"lstallation

Removal Hota ;s.tot.remori'Igrfla.~.lf~

IliOfluaingllne ....eryelolh).IIIh1~uipmoonl laav.w. . .. p/ec:.,I>tbo/tInV-b!ock.and ........... the n.noutUllng.diIIlncicator.Wlhebollilbtrll

must ber~.

.0011'_.

_,....-----..~;;;;;~;;;;;;;;;;;;;;;;;;;:;;;;:~

s

5- 16 Frame. suspension and final drive

.~_'\~ \.'~~

'..c> _"'" (;'t;"

Inst. ll. tion SI.,.,an.,lon r . t h e . _ ol.lITIOYeI.On completion ed/u.! end lubricate the chI>In /GlOwIng the procedurft$ dItctIbId in OwtpI.I . ~~ Uti only 'h. nocomm_

15 Sprocket1; -

check and replacement

14.2bEngln6 . prockllCO\l ... boItl ('mlwed)-~modeI.

=="'C-.,~c--_ Check

~~.::::w..~-:':I== notlng-'Y~mo>rksl"'lIIuslntlon

14.2a).Mnol'l'llt1<s"oisibIe.mIIlinkagearmpinch boll Ind ,.mo .... the I.m I.om the all.t!.

.&.

noIing-'Y~mo>rks(.-il ustnotlonl.

10 the CflnkCII. . and .emove it I... lIiuI '"lIonl , . On 550 models. ""screw lhe

~lhechllin " eplacelhesprOCke4'" on~. cenlre stand. 0< ~ '*'II an III.nfllouldn'fI.kelongerlh... cMIn _.. _-Hif _ bldenYged. I... minu, doea, IhI O-ring. In 1111

Sf*'I the whHI_,econ::I Ihe ........ nt 01 ~ino;Iicalod."1heamount....:eedl1he

.....rc.1miI1PICifIod.rep!aoelhesproclesprocl<etand chaWloff the 'Ihg. then remo~e the sproCkel.notlng.....t\ochwayrour>d~fils l _

I F\enIovoI lhe re8< wheel I_Chapter 6) C.uI/on: Dg""lla yUMwhHldowflotrlha

::;~t=::"'b=:S:~;;'~;,~':':'II: tile "flNjt>d. 2 Ul! lhlap.ocketcoupliflgawaylfomthl

oft

_.-

wtv.tIlItion).

wtIMIlNW!g!herubblrd;wnperslllpositicn

17 8elorllnltalllr>gthefllWrearsprocl<et.

III !he whMIl_ iHullration). Note the

check the wheel coupl"", and damplll"

~"'klethecoupli"".Checklhe

......-GIy~I_Section'6).

couplllloglotcracl<soranyobvlous.q.,.01 .s.mag.. Also check the sprocket studs lor

,8 ln1t11th1tpOCke10nt0thlCOJPli'"o!lwllh thlltllJnpedmnt.cingout.tIWltightenllM tproeketnutltO!helorquesettingspecified IIIth1b1Qitri"1gol!heChapter. ll1 lr-.taI!he..-wheet( ..... Chapter6). 2O AdluetlJ>dlubf'lcatetheCI"Ialnloilowing lheprOOlClur. . dllCribedinChapterl

3 Ultthlrubblrclarnper"","*"lfJOmthe .....t>eeI.-.dd...:l
....... ..... 1~

Braluuystem-bleeding .... .. 11 B,ake systllnl- cIleck .... .. . .. ............ .. ... seeOlapt... l

Tl'flIS -lI"""falrnormationandfitting. .

F.ootbrake caliper!l - ,.".,...,...al,OYfJIt\a!J and m taUation Front brftk .. dioc - insp
5

WheeIs - aiigm'08!1tcheck

~:: =~~==~'~tion..

G_alinfonnation

,!

Wheels-

k\$peCliooand'epa~

WheelsandlyfBS -gener&ld>llCk.

. ............. . . 17 ..... 13

........................ 12 . ..........,....,ChaPl... t

1

Degrees of difficulty

Specifications

4.35mm 1.0mm 4.3mm 1.0mm

::~~.6mm

5.8106.1 mm 5.0mm IessIl\llo"lO.2mm

0.3mm

Wh.... MaximJmwheelrunoul(frontar.drearj A:n on each end of the padlocatesag~n$ttheguide($Hlllustnrtionl

the disc. Remove ttle R-pin from the end of ttle pad retaining pin. ttl8n withdraw the pad pin. Remove the o~ter pad from the cal iper body. noting how tile protrusion on ttle end ot the pad locates against the guide. lift the Inner pad off its guide pin on the calip8f mounting bracket. noting how it fits 3 Inspect the surface of each pad for contamination and check that the frict ion material has nol worn beyond ~s service limit. If e~her pad Is worn down to, or beyond. the

solvents on internal brelre components. Solvents will cause the seals to swel/ and dis toff. Use only cleM brBlre fluid or e1anaturad alcohol lor cleanIng. Use CBre when w orlrlng with brake Iluid BS I t can injure yewr 8)11S and it will dam;tge potInted surfaces and plttStle parrs.

2.13 RemoYelhe outer pad . .

2.1 b . .. thenslidelhecaJiperfuUylnuntit thelflflerpadcanbe lifledoffthllpins

-w>e limit ~ step, line Of g"""'" (Ie lhey lII'enolonget""'blel,ICIOIedwilholiorgrease, or heavily scored ordllmaged by dirt and debris,boIh pads m()!ll bfI replaeca/iperand,*",1~

a sourceofcompressedairtoblowoullhe pistom,ju5l/oosenrt>ebMfoboltMlms~

endre/iglltenll/igllI!y,7hebike·shydreul/c $)'SIemcanl/letlbevsedlOlOtcelhep/slOt'l$ WI of the bcdy OfIC. lhepad$ have bHn remoWNJ.Di$connectlfleho$lJOCelile pisk>ns~_wlfll;ier1rly~.

2 Unsc,ew the cal lpe' mounting bolts . and

3 Froot brake calipe(sremoval,ovemaul and ins1allation

~ ~~:Ir~~~t~~arh:r:k~h~~~~~

~ ~,,:~z:~:.a::~~=" the pi.ton

.& E~~~::~~fz

operelion},elloldbrake"uid shouldbe"uShadfrom Ihesyslem. Also, the dusl erN/ad by lite brake syslam may contain .sbnt.... whichlr harmful to your health. NetIfNbIowitouf,mh compreasad a~amldon'tln".,.anyoflt.AnIpPfO_

flltaring mark should be worn ",hen "'_orkin9on tlteb. nt, tc>clean br. ke p.rts. Useelean br/Jkefluld,br.ke cleenerorden.turee caliper bores.

levelline ... ~hlhe speci l leo:t br a k ej luidl_ l!Iuatration 5.24) ano:l bleed the hydraulic syst&m as described in Section 11 17 Ch&eklOf leaksano:tthoroughiy testtl>e operat"", of lhe brake before riding the molorcycl&

:.:oo~~:'tt ~s~=~= c ellperbores. Using yOUf Ihumbs. pus h the pislonsall lhe ... rII'/in.mal!ing ...... theyent@< 1I>eboresquare!y (_ UIuSlrfllon7.11j.

Insta"atlon 12 On all e.cep1ZR750 0 moOeIs. inslalilhe piston canl •• pie¢.s (sea illu st.ation 3.2b).ln$laIllhtobralcepads(oeaSectlon2). 13 10stall Ihe caliptlr on the brake o:Ilsc malcngaurelhepadssil square!yeither sio:te 01 lhe
gauge 10 e fori< leg, ... ~h lhe plunger on Ih' gauge toocNog the surface 01 the disc about 10 mm (112 inch) from lhe Dowlhaym(.... ill u.trationj .lay the parUOIJllntheproperordert0p'"vent eon1usiono:l.o:'ing '..assembl\l(.... illustrationj 13 Clean all pan. with clean l:H"akelMdo' deNltu,ed alcohol. II compressed a i, i. available. use It to dry the pans tl>orOllg hly (makes<xeil'sli~eredand ...wbricatedj Caut/oll:Do nof, undar"nyclfcumsfances, unllpe tror.um-bllsedsolvant tocr.lln

CUI

bnlkapllrf,.

I . Check the maste, cylinder bore for COffOllion.!l(Htches.nlcl<sandsc....

....n...

II damage 0, wear is evident. Ihe master cylind",must be ,eplal:IId"';1h a nawone.lf tile master cylinder is In poorcond~lon. then thewpers should becMcked nwell. Check that the fluid Inle~ and out let pons In Ihe rTID!ItercylindllrareciMt.

~~ ~~~o;,,:,~~~~u:~" s:~.= ::'~':':.lessoftheapparentcond~ionOf

8

6- 8 Brakes, wheels and tyres

6 Aear brnke pads replacement

A

~~::c-;:-c---:-:----,-----'

t9 lnsla1lthebrakelight swilch 20 Inspect the reservo .. cove.

rubber

:=~t~. and re~ace 11 damaged or

Installation 21 Attach the masta. cylinghaod pressure only (oee illus tratioo 7.11). Due 10 lhe Increased frlclioomaleria l t hicknessofnewpads.~may

benecessary loremove themastercylioder ~~anddiaphraomendSiphonOUl

B Smearlhebacksofthepadsendlheahank 01 the pad pin (ZR550 B4. B5 end B6modg and guides ar" correctly posltionfld (sea IlIus lraUon 2.icalescorreclly agains l its guide (see IIklstratien2.9b) 10 OnS50B4.B5andB6mode1s.irlstallalion 01 I hepad "8 n dpadpini. lhe ,ever~0 1

,emovlll.Makesurethepadspringandguidfl are correctly posltiooed (see Illustrations ). Make ..,re lhe e uterpad Jocatescerrectly aga inst the guide and tha brac ket (s. . iliustrltlon6.2d) .lnaertthepadslnlelhe callpe< so Ih at the Iriclion materia l 01 each pad will be lacing the disc (see illus tration 8.2c). 0r1 B4 modeis 10 Irame flO . 024010. ~ t the .him onto the back of the Inner pad w~h lhe open end lacing back. Make sure lhe pad

can II!en be IJ$tKi 10 f""",'hepl$lon. 001

pin pasa8sthrougheacllpadand.IIC",elt witll lheR· pIn (oee lliustratlons 8.2band a) 11 Install the calipe
your

::,'::::3:'::,S:C~

Ihemwhenspplyifl9~

alr,HserloualnJUrycouldfltSun, S Using a woodeo plastic 1001, remove the dust seais from the caiiper bores and discard them (aee illustration 3,S). New seals must be used on ins/allation. Ha metal tool is being usad, take great care not to damage the caliper bores.

or

6 SJiderpinboot

7 Slider pin boot 8 Caliperbody 9 BJa&dv8/Ye

II Padspring 12Pi3ton

13 Dustseal

10 Plldgu/de

6 A8OlO'Ieanddiscardihepistonseaisinthe sarneway 7 CIe8f1 the pistons and bores with denatured alcohol,clttan brake Huid or brake system cleaner. If compressed air Is available. use it to dry thtt paris thoroughly (make sure it's fiReredand unlubricatedj. Cautlon: Donot,under anycircumstance3, use a petroleum-based solvent to clean bralrepart& 8 Inspect the caliper bores and pistons for signsofcorrosion,nicks and burrs and loss of plating , If surface dttfocts are present, the cal iper assembly must be replacad. Check tha\ \he cal iper body is abie to slide freely 00 the mounting bracket siider pins. If seized dlJl'l to corrosion. separale the two components and clean off all traces of COffoslon and harderledgrease. Applyasmearofcopperor silicone-based grease to thtl mounting bracket slider pins and rtlassemblethe two componenls (see illust ratlon3,Ss).AepllICtt the rubbflr boots II they are damaged or deteriorated (see lilustratlon 3,Sb). lI the

=,:~~~nt!~~= the master cylinder 9 Lubricate the new pistoo seals wilh cltlan brakelluid and install them in lheirgmoves In the calipef borH. Note that 00 750 models, two Si:.:es of bore and piston are usad, and care must therefore bfI taken to ensure that theCOrTeC1 size seals are frtted 10 thtt COfTeCt bores. The same applies whe!l mting the new dust seals and pistoos 10 Lubricate the new dust sealswlth clean brake fluid and Install them In lheir grooves in Ihecai iperbortlS 11 Lubricate the pistons with clean brake ftuidandinstal l lt1emctosed-«ldfirslintolhe caliper bores. Using your thumbs, pushlhe

Brakes, wheels and tyres 6- 11

..

a ~:~v~a~ ~~ai~~ion, ~ Inspection

1 Refer to See pedat

9 Rear brake master cylinder - ~

~~~~,ra~\~Verhaul and

~

11! th
the brake is appfied,and bleeding thebrakas does nol help (sae Section 11),andthe hydrauliehose$arealllng.ood cond~ion, then master cyfinder ovemauf is recommended, 2 Bofore disassembHr>g the master eylinder, read through the entire procedura and make sure Ihat you have Ihe correct rebuild kil Also, you will need some new, clean brake flufd of the recommended type, some c lean rags and Internal clrclip pliers, Note: To prevent damege 10 thfJpaint from spilled brake "uid,aJway1lcoV/lfsurroundingpalnred surlaces when wortingon the maslfNcylinder,

Caution: DI:sassembly, overhaul and reanembly of the brake muler cyllnder musl be done In IJ:spolleulycleanwork IJreIJ to IJvoid con llJmlnation IJnd possible

failure of Iha brake hydraulic system componIJnts.

Removal 3 Remove the seat and the right-hand side panel (see Chapler 7), 4 Unscrew the brake hose banjo bolt and separate Ihe Ixake hose from the mastar cyl indar, noting its alignment (see iIIustrationsl· Oiscard the Iwo saal ing washers as thay must be replaced w~h new ones. Wrap the end of the hose in a ctean rag and suspend the hose In an upright position or bend ~ down carefully and pace the open end in actean container. The objective is to prevent excessive toss of brakefluid , flu id spills and syslemcontaminalion. 5 Unscrew the maslereylinderflufd reservoir cap and remove the diaphragm plal e and d iaphragm (see illustration) , Saparate the Iluid reservoir hose from Ihe elbow on the maslercyfinder by releasing thu haseclamp, and allow Ihe ftuid to drain from thu reservoir into a suilabte container

6 Removathesplit pin from the clevis pin securing Ihe brake peda l 10 Ihe master cyfinder pushrod (s&eilluslralion) . Wilhdraw thec~ispinandseparale lhe pedalfromlhe

:~~r~;!'!~ard Ihe split pin as a new one

7 Unscrew Ihe two bolts securing lhu masler cyfinder to the bracket (see lIIuslration).

9.7 The maslercylinder Is secured by two bolts (arrowed)

Brakes, wheels and tyres 6e13

9.1011 Rearbrakeme.ter cylinder components ISplitpifl 2C1e';spin

3 Mas/ercylindo!r mountingbolf 4

~

Mastercyfinder

:o..1>3se .-

7 O-ring

'''"'''''''

9 Rubberduslboof 10 Cmip 11 Pi5ton....".-nbly

,,""'" :~=.a.~ Overhaul

~h~ n::~:Z't~~a~~i:h!it~~~ ~k:~~ tockn~1

and 'emolle them from the push.od

l_ilhl'5tflltlon). to Dislodge the rubberd~st boot f,omthe base ot the master cylinder 10 'eveal the pusfYodl'9lainingc~clip l_ lIIullr8tion .) .

11 Depress the push,od arid. ~sing internal cj'cl lp pliers. remove the clrcllp Is" iIIust,ation). Slide out the piston assembly and spring. II they a'a ditficult to ,emova. appIylnWPf ........ compressed ai'toltleflvid outlet. !.ay the part. out'" the proper order to preventconfusionduringrea55flmbfy

t5Reser>lOircap

:~~p/efe 18 : : : : : : 19 Reservoir mountingbolf

"'..,.,"" g~sher

::=:~.withcleanbfakelluid CaVflon:Oonot, unde
~~:n~l~h:l~r~~:)~h~~~~e ~:~:s ~~~~".:!~ ;;:;~~:: f~~:s,

as

I~e

are COOlffion

3 Inspect the metal banjo union fillings comected 10 Ihe brake 00ses. Hlhefillir>9s a", rusteci,"""'Id>edorcracked,replacethem.

Replacement 4 The brake I>oseshave banjo un>on'itttnos onaachend !. " llIutlr8tion).Cover lhe su.rounding area with plenty of rags and

Brakes, wheels and tyres 6-1 5

ooscrewthe banjo boll on each end of the hose, noIing~5aliognment. Fr...... lhellose from any c lips or guides and removelha hos • . Oiscard the sealngw8Shers.

~=~=~r~~~':~:~l~

passad through any dips or guides. and abut theUlb on the hose union wilh the lug on tha componantcasting.~present.O\IlEIr"'Mse

alignthehoM ... noIedonremovol . lnslal the benjoboits.uslogoewsealingwashersonbolh aiclesollheunioM. andtightetlthem tolhe \orQUeseningspeciliedal thebeginningolthis CIlapteel loracCflsstothe lluld 5 Remove the rese.-voir cap/cov .... dlaphr8gm plate and diaphragm and slowly pump the bfake lever or pedal a lew limes, 00111 no a" bubbIM can be seen fIoallng up from lhe holes .... the bottom 01 th. reservoil" Oolng Ih-is bleeds lhe ai, from lhe mast" cylinder end 01 the line. Loosely refll Ihe .--vol. cap/cover. 6 P\lll the dust cap on the bIe«I vatve 1_ ~lustration) . Attach oneeniIce and the

.

7t!'=~~~~::~~:f~

=

3 An easie r,thoygh s lighllyl ... s accyrate , metho(l i$foattachastilf wfre pointer to the

:i~;c~o~h~~:~~~~ ~:::~~~h~

iwf*elhe_andtyrejoin). lf thewheef i$

:"t.!~=s':'=~~~a:~t':= Ifwheelnmoul la exCfiSi .... cl>ecktllewhetll

13 Wheels - alignment check

~ ==sd~~a:~~~!r~7~eE ~ ~~=e.;,I~n~S:~t~

t M Isa~nmeot 01 the _ s, which may be duetoacockedr"",wheelorabent lmmeor fotk yokes, can C8U" s trange and posslbfy "nOUS handling problem •. If the Irame or yoIces are at lau~. (epa~ by a f,ame specialOst ; ; : t = e nt with new pans are the oo'Y 2 To chec k the align"",nt you will need an asslslanl . alenglhofstringoraperlect'Y st.aightpOeceolwood8ndaruler.A~vmb

::,,:;gSVereplaclKl with a new ooe . Never attempl 10 ,epa;. \I darnagedcasl a~_ .

5 On$pOl<ewheef modefs,cl>ecklor\oose or brol<en spokes. Tapping the spokes with a screwdriwrislhebeslgvidelo lhllif lension. A loose s poke wi ll ma ke a dull Iial note compared 10 a light one. l""""spok"" must I:>e tlghtenlKl by turn ing the nlppte at the spoke end in an anti-clockw ise diflICl""'. Afways check forrunoulaf1er allefing lhe tension In any of the sPOl<es, Small Irregulafitlescan be co""ec'lKI by adjusting the spokes In theaffect&d a.e • . although a certain amoynt 0\ practice;s neces'Bryto prevent o.er-co.nlction. If the wtleel runout continues to I:>eexcess;"e. takethewheef toa profeWonal wheel buik/er for inspeetion and adjustmeot.

wllat>e weight will also be

!!..::~ai~~:: t~~~:: ~~~~

=S~~!"::~~It'~:;h~i~~~ ~;If::r=~ht;7t ~lhe=.~ween the"oot and ' _lyres

4 I1astringls used. lIa""youressistanl hold one IIfId 01 ~ Itbouthalfway between the floor andll'lereara..Ie,touchlngll'le ,_sidewalioi II'Ielyre. 5 R""theother end Of the stringtorward and puU ~ tight 00 that rt Is roughly patallef to Ihe IIoor.SIowI)'bring thestrlng lntOcontaclwith II'Ielrontoidewa.li oltherearlyre,thentl.mll'le I r Olltwheelunt~lIlspara l lelwfthlhestring

Measy.e the dis tance from the Iront tyfe sidewall to the string flR~tthe procedureOllll'leotl>ersid e ol

the motorcycle. Thed is tance l,omthe frOOI ::,=a~tOll'lestringshooklbeequalOIl

7 As was previously po;ntlKlout, a perfllCtty straight iengtholwood may be subsmutedfoothe string. Theprocedura i$lhesame.

f4.1Un..,.. wtheknvrlednng(a~anddet.aCh t hecable

9 If II'Ie fronHo-back aligM'l8l"lt is COtTecI. the wheelsstil may beout01 alignment vertical'Y. 10 Using the pi umb bob. or othersy rtable ~ht. and a length 01 string. checl< the rear wheel to make ...".e ~ is vertical. To do this ,

~~'::~w=:r~t::n~=t=

Wl\enthestringtouchesbothlheupperand lower ty,e sk!ewalls and is perfecttystraigllt. thewh ....1 is .ert "'al. ll rt is not, place thin

~~~~~m~~~~~~~~ wh .... ls a, e nol perfectly ""mcal, the fra"", =or malor s uspensOon components are

14 FrontwlMel -

removal and inslallatjOl1

Removal 1 Uns crew the knmted nng securing the ~ ... cabletortsdrivehousingOIl the leh-hand side 01 II'Ie wheel hub. and detach thecable (see illustra lion). 2 Remove Ihe Jelt-hand brake cali per mounting bolts and slide the caliper off the dls-c (s ee 11I us tratlon3.2a). Supponlhe calil*'withapieceo1wireor abahIyIlncl.ha'aoY"" ...... """ ....., .. 'i>o ~ .... odjusl .. tum . . . _ , " " " ....... lha' poa;tiDn,_ 101110 cUI"'" '" -00 _ 01,,,, . winl/ar .....

-" .......... "' tt>e ..... ".,.,~

........ _t>oII..

31\omooe 1ho,OIMWtgdlplromlhouloonut

:,~.,:u:~-~,:,:, ,~

'::..&;':, I::

.............. _d

=~~'7n::~i. S~~,::~=

''*'kl ..... ",.''_lOlheg'ound(.... jll~.tr.'ionl,

NOlo ...... ,!Ie ~".. pa..es ,... oug/I ,,,,,,,,,,,,,, ""heeolper,,,,,,,,,,,;,,g "'acIteI_The"' __ .."ohoUId~

.... ca'JIIII~ .. ~""'-H~_·,. chec:kll'lol'ho_ ..... ....,.. ...e llgh!""'" lo'''''opeci!~IDll . Ot'-''' ... ~'''''~ pIa.ooolonlho_ S DioongIgelhoodleOtlromlhoop>OCket_

... '''''' no.''.... ..

'-=vtIIho_!r","''''

_ , ....

.~''IIomt

_.""'"I>OI~oidesoltl\e

=:::,:Y",,~,,::,(=


15.IOb Make sure the disc lilscorrecUybetw&en Ihe brake pads remOV&lhespac&rfrom Ih&cal'p&rbr&ck&t (s&eillustralionI5.9) Caution: Do not lay the whflfll down and allow it to rest on the disc orthespr!lCketthey could becomtl warped. Set the wheel on wood blocks so the disc or the sprocket doesn't support the weight of the wheel. Do not operate the brakep&da/wlth the whee/removed. 6 Ch&Ck Ih& axle for straighlness by rol ling il on a flal sUl"lac&such as a piec&ol plal&glass (if the ax l& is corroded. tirst remOV& the corros ion with fine emery cIOlh). II th& equipm&nt is available. plac& the axl& In VblockS and measure tM runout us ing a dial gauge.lllheaxl &isbenlo,lh&runoul &xceedsthelimitspec~iedatttlebeginningof

ttleChapter. ,e-placeH. 7 Ch&cklhe cofldiHon of ttlewheel bearings afld bearing seals (seeS&ction 16)

Installation 8 Apply a thin coal of grease to the lips of eachbearings&al,andalso tothespacers.

15.11 nghtentheaxlenutto thespeclfledtorques&ttlng

Using a 12 mm Allerl key fn &ach of the chain adjusters, rotate them so that the axle hole is w&1I forward in Ihe sw ingarm (about 9 o'clock):&OSUf&lhat th& same adjuster mark aligns with Ih&cutout on &ach sld& of the $wingarm, then tighlen I h& adjuSI &,clamp ~tstolhespecilied torquesetting

9 Install the spacers into th& WhHI (s&e illustrations 15.5a and b). II,emoved,alsom Ihe spacer inlo Ihe brake caliper brackel (see illustration) . Mano&Ov,e th& wh&lll so that il is in betw&&n th& &nds 01 the swlngarm and apply a thin coat of g,&ase to the axle. 10 Engag
circJ ip.makingsure il iscorrectlysealed inits groove (s .. ", illu stration 16.3b). Apply a smear of g, ease to the lips of the bearing seal. and press it into the righi - hand side of th .. wheel using your fingers , a seal Or bearing driver. a suitable socket or a flat piece of wood (see Illustration) . 10 Tum the wheel over and install the bearlng spacer. Drivetheleft-hantlbt;;:";nginlopiace as described above. Fit the speedometer drive inlo lhe hub. making sure the tabs 00 thedrivelocatemtheslotsmthehub,thenfit thecirclip,maklngsure~isC(llTectlyseatedln

ilsgroove (see Ilfustratlons).

11 Clean off all grease from the brake discs using acetone or brakesyslem cleaner then instalithewtleel(seeS&ctJont4)

Rear wheel bearings 12 Remove the rea r wheel (see Secl Oon 15) Uft the rear sprocket and sprocket coupl ing assernblyoutofthewheel ,notlngtlowrtfits (see lflustratlons)

13 Setthewtleelonblockssoasnolloaliow theweighl of Ihe wheel to rest 00 the brake d isc 14 Using a rial-bladed screwdrivef, prise out the grease seal from Ihe right-hand skle of Ihe wheel (5... illustration 16.301). Discard Ihe seal~itlslnanywaydamagedordetetiorated

as a new ooe should be used . Kawasak i recommend using newonesasa mailer of COUfSfl. Using a pai r of Internal clrclip pliers. remove the circlip securing the wheel bearing in the hub {see IlIuslratlon 16.3b) 15 Using a metal rod (prererably a bmss drift punch)inser1edlhroughlhece-nt'eof the righ t-hand bearing. tap evenly around the Inner race of the left-hand bearing to drive it from \tle hub (5.... illustrations 16.4a anclb) Th8bearing spacer will also comeoul. 16 Lay the wheel 00 rtsother side so that Ihe remaining bearing faces down. Drive the bea ring out of the wheel using the same technique as above. 17 U the bearings are of the unsealed type or

8

6-22 Brakes, wheels and tyres

18.12b Utltlle::':"'w.:':!COupiingoutol

SproH!ulingyoOU' fing.r. , . . . . l orbe..lngdri• .,." •• uitat>le sockat Ot • rrat piece 001 wood lse. ifIus'rationI8.9b) 21 T.....,thaW'IIN<MO"andinlltllllthebearing

spltC«. Orivethelelt·handakleblarlog intoO ~lIIIdeecribldalJoo4,

lL24l1 Sproc:katcoupIingcCllTlJlOMflts

, GtMsIMfII 2CiraIP

38MMg 4~

HI.24bR.mo"' tIIe ~ ...

""'tIMocoupling

from


16.25~t"-bearingoutIrom Ihe 1n 5ide

16.29aDrMot"-bNnnglnuntil seatlKl

uSing a socket located 0ebearirogspinasyoudryit). AppIy a lew lIrops of oil 10 the tJearing. Note:/lrhfl

29 Thoroughlyclean thebearing receout",,,,,,,,oft1>e bearing, Aisingtemperat ....,

fromze
etl TC

3.Qlo7 .2 Kohms 43 K ohms

at 25"C

Starter motor

Alternator

Regulator/rectifier Regulatedvoftage ..

Torque settings F~=a~~erCY"nderclam~tloftS

~!:.=::~~.dl

..

:::at,:;;:,;:ting boM (750 models) 55O~s

..

Aliemat(lrstatorboM .ssomodejs ..

llNm 8.aNm

15Nm 15Nm

Electrical system 8-3

1 General information

AU models have a 12-V(l1t electrical system The components inc lude a three-phase IIltematorunit and regulator/rectiflflrunit The regulator maintains the charging system output within the sptcilied range to prevent ove rcharging, and the reeendof this Chapter 10 pian where you will make the necessary connections in order to accurately pinpoint the trouble spot 5 The basic tools needed foretectrical lault linding inclu(leabatteryanclbulb teslcircuit, acontinultytester,atest light,andalumper wire. A multimeler capable o f reading lIolts, ohms and amps is also very useful as an alternauve 10 the above, and is necessal)l lor perlormiog more extensive t85tsand checks F~II details on the use of this l est equipmenl are given In the Fault Finding Equip ment section at the end 01 the manual.

3 .B attery -removal,.installalion, ~ InspectIOn and maintenance ~ Cautio,,: B e eJlfremely caMfu/ whe" ha"dling or 1O'0rl
Rnsethebanerythoroughly.lhenrkyit. 1 L.oo1\lorcracksin\hecsseandreplacelhe batteryilanyar.found.llacidhasbeen spilled On the frame or batlefY holder. neutralis, it with a bakIng soda and waler eoIutIon.rky~t~.thenlouchuparry

dafna\led paint. On ZR55OBI, 82, B3 and B4 modeIa,make~.lheltheba ttflJ)'v.1lhose

I,routed corr8(:tly afld Is not kinked or pinched.

8 Illhe motorcycle sits unused for ~ng periods 0 1 time. disconnect tile cables Irom thebaltefYterrninals.negaliveHtefminai fnt.Ref... toSection4andehargethebalte'sservic.-~fe. If /he bulb i$ acQd8nraRy touched, it $hOuId be

wipedCMflfu/lywheneokJwllha'Wi1le way. /I is. good idH 10 pilptN towel or dry cloth whet! handling tile new bulb /0 prevent Injury If the f)uIb should />reM ¥Id to KIcIN5e bulb ~'fe 3 Instal l the lenl onto the tall light, mak ing smethe seal ing rubber is corre
OFF check is complflte. Also ehee k lor continuity l)etween the relay tflm'linel$. Thllfe should be contino.ity(zeroarclosetozeroresistanoo).lfa resis~ reading at more than a lew ohms is shown,replacetherelay. 411 nopowerwaspresentatllleretay,check thewiri"'llfromther~aytolheignllion (m ain) $W~C~

lor continuity.

!5llpo_waspresentatth&reiay,u$ingt~

appropriate wiring diagram at tlJe end 01 this Cllapter, check lhe wiring belweer1 the relay, lurnslgnal switch and turn signal lights for cootinUity.llthewiringandsw~eh are!lOl,lt\d. replece the relay with a new one

14 Brakelightswitches checkandreplacemenl

Circuit check 1 Befora checking any electricai circuit. check the bulb (see Section 9) and fuse (see Section5}.

8 1 3.3 The tum signal relay is behind the lett-hand side panel

8- 10 Electrical system

2 Usinglmullrn.t.OtrHrlgh!t:OIYIOCt"" rOlgood..".{gtQund).chK:teI. and_ Ihe rim OIl! oIlhe II'1II. llOIing how ~ fits I...

::=-~-~::~~

Ihec:onnaclOfSlnlidellMhNdIighl al>al. F-..lfllwirlnglrcm..,.dipo..-Iieoo. 2 ~Ihe~t_cabla .. tllrling r\ng from tl'le back 01 lhe spaadomat.. and detlChIheCltlla I... · 1us1J'ation15.5j 3 UnlCrIW tile two ..... ts aac....nr.o till qli\llTllfl!clulr ... lorh .undersideollhe l~ yokaaodc~ellIIYrerncweltlaassemblyfrom

the yol<e. liking care not to snag thew,l'Ing and noting Hs routw.g INI lIIuSb"ationl • Installarlon ~ t ha......-ot ,,,",,,val. Mak. s.ura lhalthaspaaOornata.-cabieand wirlnO C«o:lIICIOfS ... corractIyroutedandlS8n:f4~.Tum t"'igniIIon.~ON .Connect"'''''''''tsd

jumperwlrsbDWlhe ""'all IUO locates '" IheI>Dleln,hebrackel (seelliu l lrllion tll.4bl. UnKrew \he single ""'_ securing 11M cuing and wlthdrawlhetachomet., lrom rhe Clling (I . . Illustrellons) . Removs 'M IK~I.,wlrlng5C,eWSandedON,lhe lue! ga"lleshoukj read F (lull). and with the Ignition switched OFF It should read E (empty). If rt doesn't, chtK:1< the winng between the connectOf and Ihe gauge. and chtK:kfQf voltage at the brown wire on the back ot the Iue! gauge. If the wiring is good then the lI"uge isfaulty.

~~~~UO;:~~~-::;~~~k (see Section 26)

Replacem e nt ::c::'et:,1

~:~rft :~ 1~~,,:ra;ac~i~':,,:I~~

re~acement

procedure above. "the fuel

then push the bulbhoider back into the rearol

'M_ ~t~

=:, ~t;;:;~~ I~~:::'~~;:t~

IseeSectionI5),thenremovethesingleecrew securif'lQ the fsar cover (... e illuslretion 15.4a) . Remove the Ihr.... small sc rews secur'ng the wwong Ight panel to the cluster, Ihtn separate the pane!,noting I>ow the smal

::S!.v~~

:=":t ~u~~a~~,,~

';: panel . tl>en gently pull th. bulb out 01 the bu1b/101der {s"" lIIu$lrotlonSj , Care!ullypush the new bulb Into position. then push the bulbhoklerbackintotl\erearotthepa ......

Check 1 Thotoil pressurewaming light should come on when the ignition (main) sw~ch Is turned ON and extlngvlsh a lew seconda a1terthe enginelsslarted. lttheoiip'""su, .. light comes on whilst the engine i. running. stop the engine immed iatety and cafryout Bn oil p"""SUfflcheclSe8Utral,there should be continu ity. With the transmission in gear, there should be no continuily.ll the testsproveotherwise, then either the switch is faulty or the I'>8Utral pin has been incorrectly Instal led in the se!ector drum (this is only likely If the gearchange selector drum pin hofder plate has been removed). 5 II thecontlnully tests prove the switch is good,sw itch the ignition ON and Check lor voRage at the wire tenninal using a test light. II there's no voltage present. check the w ire between theswilch.the instrumenlctusl er and fusebox (see the wiring diagrams et the end 01 this Chaptetl· lithe wiring is al l good, removetheseiectordrum pin holder plate (seeChapter2,$ection2Q)andchecklhatthe longer neutral pin Is correctly pos~ionedinthe drum,an.dthat the pin fits into the correct hole in the holder plate. With Ihe transmission in I'>8Ulral. the pin should align wi,h thecontae junction bruc is good . cl>eck I!>e other compooeolsln lhtl.larterdreuituclesaibed In the retevanl sections 01 this Chapter. II all the componants are satls factDetwoon thtlvanouscomponents(raf... to Ihe wiring djag~ms at the and of this Chapter).

ISH

ChaptM3)

Replacement 6 Remove I!>e seat lsee Cha!:>te< 7). 6 Slide thtl Junction

in

thespecifocations at the beginnlno of the Chapter. Altemativ,"y. remove the sender

bo~

out 01 its hold« and

5 Priseollthesendeo"ooverllSlngallat-biaded scrawdri_ t.... i.,ustretlon).Unse
B

close to th9 Stlnsor l see Illustrelion). Note:

None of th6 components shooId be allowed /0 difflCtly touchthecoo tainer. Heatthewaleror 011 over a low Ilame, stirring it gen!ly. The

27,4 Sensor test sel- up 'Serl.'lor 2 Thermometer

8- 20 Electrical system

3

4

i~ ' -ti

iL ,

Ii ,

2

Specrtied is otltained at th .. tempe,atu r.. specilied. When the required temperatu'" 11M been reached,tum olf the heat and cIlecI< lhat thecorrectr .. adingisobtainedll.th .. tempell te mperalura Hnsor. If Ihe ' &ad lngs Dbtalrl
(GfY)

(BKIY)

i,

(WI G)

,G,

. .,

]

3

(G/Y)

( BK/Y)

~

(8K)

4.4_19

B.5-28 27.95ystemconb"olunit test

5

( 8K)

~~r::a~':::O;h~ ~:emU:'t~ ~~

ha.. cart>orellor.disc"""""l lhe wirlng cOI"lnlllClor lromlhehealert>eing,..rr.:IVed. th8n,,,",,,,,,, Ihesc",wsacurlng the heal8rt>racketandpuli Iha heatarDut Dflhe carburaltorbod"y(se .. lIIustratlon)

Electrical system 8- 21

27.14b Systemcontroiunit-750models

27.143 System control unit· 550 models 12 Theatmosp/leric temperaluresensor Is threaded into the Iront of the air fin .. housinq

=:~S~~:~~;:)i~~C:n~=== the pulse generator assembly COWlr. and the carburetTor temperature sen"", i,threaded Intotheoo.2carburettorll'lplaceoloneolthe Joining bracket s crews Is_ Illustration 27.3b) .0i~thewirngconr.ectorand

unscrew the sensor Qn the case 01 the oH tempenlturese"lSOr,lntdrain theeogine oil _Chaptert).. 13 The relay is mounted behifldthe rif.lht· hand side panel on 550 models, anKtlons 6 1~tallthtohom and securely tighten the bolts. Connect the wiring connecton to the

""" 29 Starter relay check and replacement

lead terminal •. Us!ng afuUy-charged 12 volt battery and two insulated jumper wire •. conneet the po$IIive(.) Ierminal of the battery to the yellowfred wire t8fminal 01 the relay.

~~ ~r~d~~!~~~7.~fr~~~r£~~:t~~~~~~!:h~~U~;

Check 1 H the starter eireuit Is laulty. fifflt check the 1u$e(We5«:1ion 5). 2 The ltarter re!ay G located behind the 1eIthandsi(lepa...... F\en'I
.... t..... t k>n.o<me~._oI)'O'J

ownHt~

... difficuftlo_ l_ to identify

~1"' \rIlIon). Also mal•• IT\Irk wt"IId"l...ayuplhehousir1g'~'.

3 1..IrI1Cr_lhetwo long boll. and with(l,aw

l"IIontlleinsicleof!lIemeinl"lOusiog ('" _1rIotion31. 19c:I. AIsonolelhebcatingpin '*-Ihoemggew_lhelronl.,.,... .-.d lakl c ... I"lOl to 10M II II.. lII ... lrttion 3 1.1Odj. The notch in the perimeler of IIIe f'ont cov ....lsoloc.t•• o .... th.IUV on th•

=-U:::"":=:!:::::!':-..

........

5 Withdraw the

arm.' ...... from

the

main

II NoIIng lhlcOl1'eclr.lledloallionoleac:h the t........ aI ""'.-.d

_

I,""""'"

.......... .naft0rinos. making """ : ' : : : ! t a fi,mpt'.lureonlhebtUlh

' Inspect t/lecomrnulatoCOfllinuityjinfonitlrMistance). t 2Checlc lhllronterldolltlearmat ... "sh;l1I torwom.crllCl<ed.eh/pfledandbrokentMltl. II the ""'II III damaged or worn, reptac. thl 1ITNI"..... On750modeIs.~cIleCktlle ringge.,lnthilront coyerlOd thidrill • p!nIononthelrontoltlleco_.Thldriv. pinion 110 MC..-ed by, cifclip. and till o;:hem1.,..;I . . . oIlhepinionteeth ..... tfaoo

out l_ .... ~. t 3~1he_~lorsignlolaKl<s or_.~1hfImagoetlintlla",.in

~....:IIhI~~lorcracb

14 ln1p1c1thlinlulat;.,gwashenlOdlront cover 011 seat (550 models) tor 110'" ot damIge....:lrlplacethemW.--y.

R .....mbly t l5S11dethibrushe-sback lntopoe.illonln thlirhoiderlontllabrushpla"'rId.onai • • c . US ZR750 CL C2 and C3~. pitlulMbn.oshspmgendsontolhebfwlw. On US ZR750CI.C2and C3....:.:1*.1ocaII thllIPringaodontolhetop ot tile brut.h hoIdIflOl"",lhInIlsnopresSUflonlhe ~=~~oIlM ....... t..... 11 Fit the In..... rub".". Insul.to< on IhI lermirlalboIt.theninMrtlheboltthtoughthl rear_(mainhousingonUSZA750CI.C2 ,rid C3 models) and install thl brushpl.,. ....."blylnlhe ..... c""er(main hooslngon US ZA750 CI. C2 and C3 modII.) making ...... ~tabilCOfT!lCtIykK:a l edinlhellotln lhI_orhousingt-_lnttIonj.Fl1th1

~~""",~~IMItIhI""""""_ 17 On II axcept US ZR750 C2 and C3 rnodI*, .. IhI-... ...... IheCl, _ _ oIIhe _ e h a f t ( _ 'I .....~tion) .lnIII1 tlla IlTNlturaintOtheoffsetopeninglntlla bn.II/IpIale,locatinglhecommul.t"'~

::"':'~'7hebro~ ~ : . - . : , : : : :

8 31.12 c~:ou.::: pInIon on

8 e 26 Electrical system

_ k>cat .... in it. hQjein thecov&I" I ~" lIIustratIOe dMding I>ate,k>catingthe notc!> r. its perrneter over the lug on the inside 01 the main housing.Chec. that t he k>caling pin Is InstalleOtchinthepertmeter ofthe·nggear l_ iIIust.ation)

31 .19e

Electrica( system 8- 27 7 Connaeclg tile checks , lollow the procedure. carefully to pre.ent incoffecl connections Of short circu its. as irreparable

==~s=componenlsmay ~

If a multimeter is fIOt available. the job of

~::~~~a~::tng system should

should vary between 14 10 15V. Stop tile engine and dOsconnect themeterwhen les!iog

:~m::'~~:~ I:h~~:.:~rat~ :.~~ ~~~: altemator(SIIIIbIIIow),ar.::llhel'9gUlalor(see s..cliQn35). Nol.'!lrllevolla~lslow, lt;s

33 Charging system-Iesting

~

~ ~

mote Jjk9ly lhal IheaUemaloris faulty. If the voililgil is above 15WJ1ts,//lsmomJik&lyrhIJl Ihe'"'9'JlarorisfooJry.

= •

c,.,.atoafa UltyregUIJJtor are enstanrl)' blowing

~:Z~g CV;:~~id.=I7!~~

1 II the machine's charging system is \hough! to be fault)l. pwfonn the following checks

I ""g;"" speed, end batfely overno/Ing.

Leakage telilt

nacessilallng fnquantlopplng up of

:='.~m~o"': t:::"...:a~~hec:a~f:;~a~~ L~_ ·~ _·_ _·_ ~_ · HIe<mInaI 3 Set the multimater to the rnA (mill; Amps) lunct"",andconnect~s""'ll"-b""Hptob&to

tlMlbatteryr>egaweHle<mInaI,andposillve (.) probe 10 IhediSCOl"O'leCled neoativ9(-)1ead ("al lluSlraIIOf'l). Wilh ll\emelercooMCled like lhisll>ereaditlgsllouklJ'101exC6l'ldO.lm1\. 4 ~lher""dOngex~.1IIesp&Cil illdamoont

it is tikely thaI Ihereis a sIIow wiresfrom1llealtematOf,$tartlheGngineand Incraase lIS speed 10 4000 rpm, Check the \lOftageoulpoJtandcompatehl01llemi";mum specilied at the begOooOng of tile Chapter.

33.1011 Alternalorwlrlngconnect.ors larrowed)-550modeIs

33.IOb Altematolvebeenchecked.-.dptOYllflgood. bul tllere"sti.aprobl ....... lhe'''Ilu!atOl'I ,.etIfler"",y_belltUlty. Hthia.lheCIISII. ,lther" ' 11 thll unit to fI K.... ataki deale< 101' testing. OI' S\lb$!itutlthll lllllPllCt unit ... ith one

th.ti.k"" ... n to be good and.lICheckthe .,.,~

Replacem e n t , The ' ''lIulator/.ec:hller II mounted behmd the rlght-hand side panel on Nrfy 550 lT1Os • Seg

soI\temMdenoinee swi nga,mpivol

(_ illustration 1.' )

suppor1edontl\e,amplOltVoolltailing,Mosl

,

~. ~

-:-- ';V~· t.

The wo,*bench •

.~:

Fum ••• ndfire

~::~ ~~ t~~~IYf~~~~ :t~:s.a~!~ L.:!Iu"."',;:~:=-' .,,:: ;~=C";-: ,".-,.,~-,:-,.,. m-"C' sure your workshop is 9Qu ipped with a i"e e.1inguisher $uitable 10f fuel·related l ires (Clan B lire • ilammabl e liqurdS) - it is not sufticienttoha""awater·i,IIed".troguisher. • Alw ays ensu r.. ad~uate vent,lalion is avaifable. Unl,"" an exhaust gas extraclk>n sysl em is BvaUab leioruse, ensUfe that the

f.lf\9ioo is nmoolsidtloi thtlworkshop • II wOr!dng on the fuel system . make Sure tl>ewc.-ksllopisvIOfllilaled to avoid a build·up of lOOle5. 1"l1O. app ies equally 10 fume buildup when charging a battery. 00 oot o.moke 0
o workst>op

• Proted .belorestartirlgworII.lfhanoling hot components Or fluids. wear suitable ~v::.pg

alloY
~"::":-~::"=t::a ,-spkIpinmustaiwaysbe""""oninstalation _alwaysfillhecorrectsizespklpinwhod1wi11fi1 SBJI;/yinlheshafthokl.Make ....... tI>&spklpin ,...". .... correcIIylocatedwoundlhenut ( _ Mlustmtions2.5_ 2.61

::::~.ened, theyare fatigued and •

Tabwas/>llf'sareL>SeCitolockpiainnotsor

boIIs onashaft.Aportionofthelabwasher~

bent op Iwd agaOnst one ftat of the oot or boll to p'eventit loosening. Doe !O the tabwaS\ler ~ngda formed lno ..., anewtabwa$her shouIdbeL>Sedrbed • Wave washef$ are used to lak.. up endfloal on ashaft,They provlda light springing and preveSeCiassealingwasherson drainplogs

L..:::.....--'--_ _ __

__=__

2." Plain not lAI,shoolderedloeknut(B), nylon Insf/ft nut (Cl and caslellated not (Dj

• A.pins(shapedli k.. lhe leltefRj.OfSlip pinsas theyaresometime-scaIHld,"'''spn.g and can be reused if they are otherw is.. ill 000'IQlSC,ew iS

accto.- twej_pointtype_beN .... Qrip

REF. S

Tools and Workshop Tips

is obtained. Surface drive spanneB grip tile midcllt ollheheltflals.rau..lhanlheoorrwn,

cases'"

;n;I_ltIutgooxl in d¥naged heads (see illustrallon2.211. • Siotted-lleador PtlHlips-llead !I(:'ews are often damaged by Ihe use of tile wrong sin

sc rowd/lv&(. Allen-head and Tou-head screWI are much less likely to sustain damage. II eoough 01 tile screw head is exposed you can use a hacksaw 10 CUI oslo! in~' head and Itlen use a conventional flatbladed screwdriver to rerTIOYO it Alternatively

ehas~afeava;labielors pa"'plUQ hoIe

threads. The tool will nol cut a new t hread. bul clean and trueille onginal th,ead. Makesu.e that you use the correc t d iameter and pitch 1001. Simil arl y. external threads can be cleaned up with a d'-l or a tlvead restorer m. (see iHustrat!on 2.24) .

useahammerandcoldc:hiseltotapthehead 01 tile last_ around \0 $Iaeken il. Always replace damaged fasteners w ith new ones, PIlIf9fablyTorxorAHen-headtype

Thread repair TtvHds (partieuhwty those in alumInium alloy components) can be damaged by

•

ov9f1ighlenlng. being as.sembled with diflln

Ihe In.eads. orl.om a component workIng loose and vib
cleanenddrywi!htllloidcompoundremoved 5e1$(:1 a compound to Sui! the component belng sec .....ed - a non-permaneflt geoeral Iodr.ing and sealmg 'YP' IS suItable for mas! appicaliors, bulahigl'lsu..gthtypeisneedo:ld forpermanenllimgofSludsineasmgs.."'W'I a drop or two oIlheoompound 10 the first ~ 1hreads(l/lhef_l__.lhenllYead~inloplace and lighten to 1he Specified torque. Do not apply ~.ceuiv. thread locking compourld o\herwtsell\ethreed may be damaged on subeeqo..oenlremcwal. • Cerlalnlasl....... 81.impregnatedwitha dry lilm type coating of locking compound on thei' threads. Always reneW this type of

lastenerndisturbed. • Anti'selzecompounds,suchascopper_ basedgr&aset. can be applied toproled

thrsadsfromselzuredueloe.lremetleatand

eommoo Instance Is $p3fk plug threiodsandexha!.oslsysl .... fasteners.

COITosioo. A

•

0(lI"I1fXIfIent Youmayr"ll!llldIQuselwogaugas

\Qg8tt8'1O~lhecleiwalceac:a..ately.

,-_,T""" :il.C5-

Mlcromete,.. • A mieromet8O" ;, a predsion toot capable ofmeas.uringloO.OtorO.OOlolarrillimetre. It s/IouId always be stored in ~scase and not in th e general tootbo~. It must be kepi clean and never dropped. otherwist\ its Irame or measuring anvils couid be distorted resulting In elramelohddthflsettinginplace.allowing the ~em 10 be removed Irom the micrometer •

Some microm&te.s have a vemia< scale

on their sl*ve, provid ing an even!ine' measurement t o be laken, in 0,001 increments of a millimetre. Take the sleeve and thimb le measurement as described above,lhen check whk:h gradualion on the vernier sca le al igns with that of I heannu lar scale on Ihlllhimble Note : 1"heeye nwslbe perpendicular 10 tile scale when taking the wtmlerreading -ilnocessaryrotate the body ofthemicromet.,,-to enwre this. Multi ply the ~ernier seate figure by 0 .001 and add il to the base aOO line me-asuremool figures In the examp le sh-own the ilem meas ures 46.994 rM1 (SH i llust.atioos 3.5 end 3.6):

measure internal diametef5 of components. Seleo:;t a gauge wi th the correct size range, make sure its ends are clean and inser1 " into the bore. Expand the gauge. I hen loc k its position and withd raw it from the bore {see illust ralion3.7} . Measureacrossthegauge ends with a micrometeo- (see illustration 3.8) • Very small d iameter wes (such as valve guides) are measured with a small hole gauge. Once adjusted to a sl ip-lit Inside the componlmt.lts position Is locked and the gauge withdrawn for meas urement with a mic;:rometeo- (see iliustralions 3.9 8nd3.to).

Vernier calfper Note: TIle COflV8(llionallinwr IlfId dial gauge type Ins trnmen ts are desc/ibed. Digita/types areoosiertoread,but arefarmoreexpenslve • T he vernier cal iper does not provide the precislonol am~rometer. lJut isve rsa ti lein

Linear seale (base) LIrlearscale(base)

~:nu~~:..~~ (fine)

OO.500mm OO.490mm OO.OO4mm

Total ligure

Internal micrometer • Internal m~rometers are a~aHalJle lor measuring we diameters. but are expensive and un"kely to t>e a~aitabIe lor home use. It is SlIQ!I8Stedlhat aset oftelescopOnggaugesand smallho4egauges,bothofwtlichmust beused with an external micrometer. will suffice lor taking internal measurements on a motorcycle • Te lescoping gauges can lJe used to

being alJle 10 measure intarnal and extemal diameters . Some types also Incorpora te a depl hgauge. It is idaal 10
nIor'OISIor

•

Inll" I~ _ DOlts/nuts in \heirCOl'rM:! __ .IhomIighIly_Their_

REF' ,3

u,osenlng Hquence.

~

..a . . clutchpa.n!melallpilles.

_ap«lectlyllalpla1l",p/oeoIIarpilole

....... tbecl.. nand'_oI • ...,.oIdlOdSSoClOS$s-oquerrce (see iIIus ttaijon4.4)

HqLlfM'lCtl u n l~,he

TOI'qlIII~IIw~1oIw1botJll

...... f1.

The_ IOIt OfCllA~1$ ~bythedista"effQmthe_oI

lhe"'II Ic>lhetndofll'le _ _

Toghten the last _ _ in tile ~I ied torque wrench clkkl, indiocf,linglhloIIheIOtQl)tl .. ltinghU~

•

W1NIt I. tCHque1

e WherilmorelhanontbolllnUl"""..... component. _ MGh 1151.,.,. • .....ry.

Iile~

ofton::.beirIQ appIiId to Ihe end 01 the ....; cfil,t;Io'IQtmullipliedbjtl4o manulM:\ur.r a ppHfl • musured torque to, boll ",,,,,I 10 ........ 1"-\ ~ W'iI not ...ell..... in use and to I'>oIc:I tWO com_,s

..,~.ApplylhelOal lig11l.,;"gof.t_.ThiI usu3lly lolowlliQhloning lc .SpIIcirlClorque satllng • Adotgr.. dllcctnbe~and.tt !ICIllld IO Ih.oock.t , ... Illu. I"tion 4.21 or. protr1ICtorcWlbeUMdlomark"".ngIeof movotmtnl on lhe boItInut hNd .nd lhe

w.g'...

.........-ding ...

iIIu&IrIIion4·31·

0;;::----,

, -- -. .

T/ghtenlng.equence.

e tI.c:ompCIf'IIOt iltreldbymotelhan ont 11l$1........ i1is lmPOl'tantthiltthltretaining boH .... nul. are Irg/'t ......, .. ".my 10 prevent .......... SI,,," bulld·up and dislO
5.1 Usingabearingd,iveragainsllhe • Additional leverage is gained by extending thelengthotthelev ..... Tlle!>estway lodothts istouseabreakerbar insteadottheregular lenglh tool. or 10 shp a length ot tubing over theendotthespannerorsocl<etwrench • If additional leverage will not work. the tastener head is either damaged or firmly corroded in place (see Fasleners)

of/a gear shalt tor example. you may have 10 locate the pulle< behind a gear pin,on if there is

bflaring's outer race

"-

• Operate the pUller so that ilscentre bOil c.erts p'essureon Ihe shaft end and draws tl\e bearing off lhe shalt • When installing the bearing on the shalt , tap only on the bearing's inner race - contaci with lhe ballslrollers or outer raCe with destroy the bearing. Use a socket orler>jjth ot tubirtg as a dnn which tilS OVer Ihe shaft end (see iliustrationS.5).

Bearing removal end Installation Driven and sockllts • Betore remov ing a bearing. always inspect the C
• New sea ls are usually ",sta lled with their ma r~ ed face (containing thesesJ relerence code) OOlwards and Ihe spring side towards thelluKlbeing retained. lncertaincases,slICh as a two-stroke eng ine crankshaft sea l. a double lipped seal may be used due 1o there being Iluid orgas Q(19aCh side 01 the joint

Tools and Workshop Tips •

Usa a bearing driver 01 socket wh ich

bearson~ontheO
likely

ol tha ""It link pi"" (s"" ill usl ration 8.1) Opee soft link. Tho sol! lin k pins 100. tike thoy have l>een

markinllfacing O\.Itwa rds) (soe illustrations 8.lI and 6.6j . On an un5ea1eOOplales). and alsounsealedorO' rirIgIX-nngtype • The hrSl dig it oi the numt)er reJales to Ihe p Ilch of lhecha in. ielhed ,s tan ce homlhe centre ot one pm to the cen1 reo l \hene~ t PIn (see illustr ation 8.111. Pilch is expressed in a'ghthsof an ifICh, asloliows:

8.10 Typical chain size and type mllr1dng

REF· '9

9.1 Hoses can be clamped w,than automotive brake hose clamp . .

... Or thick (:ard and sell- locking grips

Freeing and fitting hoses • Always ma ke Sure the hose clamp is m vedwell clear 01 the hose end. Grip the hose with your ha nd and rOlat e il whilst pull 'ng it OJ( the union . II the hose has hardooed due to age and Will not move. slot it wt1h a sharp knife and peelils ends ofl the un.on {seeiliustralion9 .51 • Res,sl the templ ation to use grease or soap on the unions to aid inslallalion; although il helps the hose slip over the un ion it will e
x 14.696

~

x 14.5

'" Pounds-forcepersquareinch fpsi;lbllin'; lb/in')

Kilopasca~(kPa)

.. Kilograms-forcepersqu1l'e

x 0.145 .. Pouods-forcepersquarfJinch x 98. 1

\.PSi;lbffln'; lblin'l _ Kilopascals(kPa)

centimet re(kgflcm';kglcm') M il libar(rnbary

Millibar(mb;u) Mil libarimbarj

Millimetres of mercury (mmHg) Inches of w ater (inHPl

x 0.Q1 ., Millibar (mbar) x 68.947 ~ Millibar (mbar)

x 1.333 .. Millibar (mbeexh""aljOil assesSlldalthll dlscrflllonol!heteslet. ll lhemotorcydewas Ilrs t used on oral!8 ~':kthallh8 handlebal1lare5ecllrely "'

Check that\l>ehandiebargripN~ar e

..

secure. Theysl>ould by booOedto\l>ebar lelt ed and 10 Ihe th'olliecable pu lley on Ihe

""' ,..............

canbempendbyp:x>rlyroo.rted~orby

overti!,trtlloftdl>earing!lorwomt>earinQs.The

~d~~~~~~~ ~~~==~~~~ ona surfoce plata, tllQfl performing a loci< 1o

'" With the motorcyclaoll the stand. hold thelrontbrakeonar>dpumplhe frontforl<SU\l and down (see lIIuslnllio" 5). Check that they are adequalely damped

REF· 24

MOT Test Checks

Bounce Ille rear of the motOl'cycle to cHeck rear suspension operation

leg). On models so equipped,ctleck that thl:!f8 is no oil leaklng Irom the anti-dive units.

or On

models

wi th

swingarm

Ironl

suspenslon,checkthal there is roo jreeplay in too linkage when moYf!d from side to side

Rear suspension

Wrththemolorcycleoffthestandandan assistant support ing the moto.cycle by its llandleOOrs. bounce the rea. suspensior1 ( _ ill us tr ation 7). CheeeI beariog fail",e

REF' 26

MOT Test Checks

... II tl\etyre sid9wa ll carnes a direction 01 rotation arrow,lhls mU51 b8point;ng in the direction of IlOfmal wll&ei rotBllon (s. . lII....tra\kN'll6) tI' Checkthat th.wheel .. ~(spindle)nuIS (where applicable) are propeeck MOT t".t '&qul.emenla with an olll(:lall" .,

USE. COMPETITION USE ONLY

'" Ctleckthetyre type.Frontand ,ear tyfe

"_.

General checks and condition tl' Checkln.securilyo!aUmajorlaslene<s. ~~.Mal. lairingS(whe .. mted)and

load-beIrilg compooenla. ~ .."...., this may Bffectthestructure,particulartyunde<stres.

Sidecars A motorcycle filled w~h a o.idIIca. requires RddIHoNllchecl<s rlll.llnglQll\esla blli tyol

Ihemach!neandsecurilyof at! ac/lmenlandllghtlng~.diff8ffromCOl1~centr"

Storage

REF ' 27

ga • Deftateeachlyreby5tol0psl,nomoreor

the

be~ds

may unseat from t~e rim, making intlalion dlflicult on tubeless

~ u b~&Quent

Battery

"'~

• RemveIuel!ankwlll'l

-.

Storage Starting procedure

•

• WalticklCan illfttled.lUmthlengiMO_. couple 01 timel wUh the ",.\ilion OFF to dislributeollll'O\ll'lClltMoenglnl;.lInCI,,"*,tIft 1I1i11..:1. tIido.thetonglM iIlIlwitdo OFF and thelgrlltionON.ndcranktNengin........ coupIeol l,"*Ig'NOlledwlrlngloomlape.

~oomoonenll . lIlllInalureoltl'le

19nItIonayalern il...:tlthlliheltlrtetwon'l

won.wlth'hekilllwllChOfF.,_ 'he

Battery . 1I"billtl!ryl'lasbeen~""""'"

~:!,!=~: ~~~. ~C::~:: poeitiwcablloflrsl_Ihe.....,.u.e_1ut. • On Ces not receilted .ny .nenUon • remove ~ fRII'I1ll>e motorcycle and ctIOICk its eleclrolylelevel. T09 up if """8Ssat)' then dlwge h baUe..,.1I1I-. ban.-y 'ails 10 l>oIde dlwgeand ......... checkssllowheaYywhil. IUlphation 01 Ihe platel. Iheban ...,.-. ~o;Iefectrt.and""""bllrenewecI. ThiI

pesllblelortlOvatMmoton::vct.lorwatda,

It OIInlcuiarfy likely If the ball"')' Is old

ItII!nC_lhllllhebrakefrw.oIIlO-"'once rtoleased. Brake I;e~pw piltona cat1 ,tick
motorcycle and charge il according toth. InlDfTNltionon the battery ca... ~lhebane..,

an ftn t ion ., emcr.ft~

lrom the

faiIItoholdacl'1¥gelt mu$lbe '~.

I!)ItIjg"bMn "' J~

1or'/Ongllme.ok/lullorecarCutellor .btbcl:aQetnl)'be'.... probIfIm~deposils h ~I!Ot3C1b/ocJI/et3-lIlcarbuterta"

c.\N"",

doesn',

prove

SIlCalSS/ul

I....

c&eklw whicf1l1re ~"ted t~ vMiou!l . ystems or areas """"" ma~ cont"'" the /aul!. Details of each p<Jssibie cause lor a !eulland the remedial action 10 be lakenare IIlven.In below eacn heading. FUe relev""t Cnapter.

7A1JnonrJ.-1MghNnoIH

o o0 o

KnocIdngorpjnklng _ _ Pistooalaporraltling V.... noiu

o o o

Transmieaionrdae

o o o

Fronter>dnoise $hockabeorWrdse Brakenoi&e

CiulchnoiH

FinIoIo:nvenc>se

'0011",....". light come. on

o

o o o0

EngI'lelubrlca1loneystem

Elec1oica1system

WhI!,$tTIOI'Oftagelow.Chedd ,ePlli' or 'lII>ace (Chapt8f 2).

Starter

When the engine is at Opara ~ng t&lT¥)erllt""'. onfy. ""y alight amoumoflhroltlest>ouldbenacessary.Hll>etnglneislIooded tIoIdthetfvotlleopenwtlileCtlricinglhetnglne.Thiswlllalow eOdItiooaloirtoreachtheC'jlindenl.

Checkandadlustthe ... iveclearances(Chapt8f1) Cylinder andIOI piston WDm. Excessi""w_wiII cause compression prllSSUle to leak past tha rings. This is Ul ually accompanied by worn rings as well. A lOP~ 0""" .... is _sary (CI\apter 21 Piston rinOs worn. weak. broO;en. or slicking. Broken 01 stOcking piston ringsusualty indicate aJubrication 01 carbu"ation problem lhal causes axcess carbon dapo$tS orseiZUllltl to fofm on the pislons 8r\d rings. Top.end overhaul is nacesaary (Chapl8f 2). Piston rinSt"to-groo"" cl8aranoe exce5Siv,. This is cauMd by exoess/Ve_ of thepi stonrlng~. Pls1onreplaoemenl ls

necassary (Chapt8f 2). Cylinder head gasket damaged. If tile head is allowed to become looS&.or~e~carbonbudd .... ponthepOStoncrownand comt.ouslionchambercauus""ren'lllfyhigh~on.the

headgaskel

may leak. AatOlquing lhehaad is noiaiweys

sutficient torestoretheseal.so g,,"k"repIaoemanl is~

(Chapt..-2).

REF'32

Fault Finding

1 Engine doesn't start or is difficult to start (continued) o

Cyliodert>Ndwarped.ThisisCilusedbyovemeatingor

o

imprope1(Chapter3)

o

Plot jet or a~ passage dogged. l\ernave and ovemalA the

o

IWbIeEod hoIescloQgeilfOCIW clearance excessive. This is cauud by ucesaive wear 01 the pislon ring IIInds. PistClfl repiacemenl is _ r y (Chapter 2) Cylinder head gasket d amagod. Mthe head Is a lloW6d to become

o

combuSlIonchamber causes extremely high cornpression. the head gasklll ma y leak. Re!orquinglhlthead la nolalwa)'ll sulfocienl to restore the seal. sogaskel repllIC:IImIInI is no
cl"C>wnandchamberl . t he easiestwayloremovelhltbuild~

o

Otherwise, 1t1. cylinder head wil have Ie> be removed and dec¥bonized(ctlapter2). Incotfec:torpoorquality1uel. OId or impropergradese>lluelcan cauoedetcnation.Thiscauses1he pistClfltoratt!e.Ihu!l1hIt knOCking Of" pingiog SC>Und. Orain old 1ueI a nd alwa)'ll use the .ecammendedfualgrade(Chapter:l) Sparkpjughealrange iflCOlTed. Uncontro/jeddetonationindicaleS

o

plug. raisingcyinder tempera.tul"M.lnataU the propar hotal range plug (Chapter 1). Improper airlluel mi>eOls or seizures to form CIfI the pistons and mgs Top-endcwerl>aulisnecessary(Chaptela1ueladdi1ive Ihat will d isso/Ve the adhesive bonding the carbon particles to IhIt

theplugheatranoe la looho1.Thepluglnel!ec:tbecomesa~

whIcIl leads to de1e>nation . CIoggedjets()l'an lhis Imbalanca (cmpter:Jj

Miscellaneous

o o o o o

a~leakc an cause

calisaS

Throttleva!vedoesn'topenfully. AdlllSlthetllroltle grlplreepiay (Chapter!). Clu1chstipplng.Maybecausedbylooseorwomclu~ch ~ s.. Qverhaulclulch(Ch;1tlter 2) .

Tmiognotadvancing.lgrltioncontrol""~laulty(Chapter 4) .

Eng!neC>iIlt$COSilytoolVgh.Using a heavieroilthantheona recammandedinChapt ... lcandamagalheoil pumpor Iubricationsyslem and Cau&edtagClfltheeogine. BrakllS ~aggIng.UsCl9llycausedbydetMis whlchhas ...,teredlhlt

brake piston seals. or from a warped disc or benl ule. Repair ... ~...., .

REF· 34

Fault Finding

4 Overheating o

Firing Ineorrect

o o o

D

Faulty ign~ion HT coi~ (Chll!ller 4).

Fuel/air minure IncomtCt

o o o

o

o

o

Main jet clogged. DWt, walerand _COOllminanb Can clog the mm jets. Clean tt.!ueI lapfillet. INI fuel pump in-line fillet, the IIoatChambertieaandlNljelsandcarburena ... ifices(Chaple,3). MaIn jeI wrong !IiI•. The stanerlcpressureaodoxygencontenl. Checkjet size (Chapter 3) Airf,~.clo(»ed.poOOyMaledo<m is siog(Cllapterl)

o

no.

CarbOnDuild-upinCOfT'lbuStiotIchamt>er.UMof a tuelado:ftiw lhetwHl disOOlve lh • • dhesivebonding IhlcarbQn p.arIides 10 the pis lOncrQwnandct"'ITbet ," l he~ W....,IO~1he bo,.jld·

deCarbonized (Chapter 2) ImproperlymachioedheadOWlfaceoriostalJalior101iocaTect gHket during engi""""..."bIy(Chapler21

Engine 10lId 8xcess/1fIJ

o

Engir>eoil level too low. Frlctioocaused by intermi11ent lack of IlbrIcatlon or from oII 1hat is overworl<ed can CIUH o_ _ ting.

the oil level (Cl\apter I ).

D

D

up.0!herwIse, lhecyllndeon. WOOlbearinll"<J< incClm>Ctll$sembly. Overhautenginoo (Chap1ef2)

TheoilprovidHadelin~ecoolingfunctioninlheengirle.Chec:k

~

Compression too high

o

Checl< Specifications aOd drajn to proper level (CMpter I ). Er.gineoilviscosl!ytooh9LUsing a'-"'«oiI tnan thllne recommendedinCllap""'CIJ1damageltleoilpur"r1!lor Illbricat>on sysIem as well as C4IIM on,mayba necessarytor&pai.the damaga/Chaflter2) Clutchrelaasemachanismdefectille.Overhautheclutchcover components (Chapter2j Loose clutch cenlr. rut. Causes drum and cent .. misalignment putbng.dragon""' engine.EngagamentadjustmemconlinIIaIly varias.OverhaultIMtcliJtd1assembly(Chapter2).

Fault Finding

REF'35

6 Gearchanging problems DcHIan't 11'0 Into gear or tever doesn't return

o o o

o o o

o

Gea«::/'I;a roge mechanism Slopper

o

the arm (Chapter 2j. Selector/.lopperarmspringbrolcen.AJlows&rmstollo4t,causing SjXlfadicshlft operation. Repiecespriog(C!\ap\e(2).

machineorll'omlack"I\IbrI(:.u::x..Overhmu l the~ission

(ChapCeg(Chap(er2) Ge8l'chaoge I..... re\OOl spring weakor broken (Olapter 2). Gearcnang ....... ror lillkagotarmb!Qken,Splineslrippedoolol ,..... or shaft. C8lIMd by a11awng l1>li leY« tooel lQOseorlfom

Overshlfb

~thelr a nsm_(Chap'er2)

dlOPPinglhemachlne.~r.ecessaryPl'''s(Chapler2).

ann broken or worn. Ful

engagementandrotaJy~tofshiftdrumreStyIuft.OIdorimp"OpIIrfuelcanC8UM detonation. This causes the pislOfI!I 10 rattl •• Ih.... the knocklng 01 !'ingirlgSOU"Kl. Orainlt>eoldlueland .....ayoo LMIhe reccmmendoldgradotfuel(Chap1er3). $perkplugheat rangelncorrecl.Uncon!rtlleddetonationlndOcates Ihattheplugheal,ongeisloohol.ThepUg"effeclbecorTlesa

o

VaNenoi..

o o o

andleadlo~on8lion.Ctogoed)elsoran"lea k cancallSeltlis

Irnbalance{Chapter3).

o

o o

theheaditsellwlllha ... lobe~edW1hereisftC . s.sWoe_ or damag. (Chapler 2).

,engeptug(Cnap1erl ). Improperaltlluelmixtllfl!. Thiswlllcau""t!Mc)"Indtnto,unllol

PI.ton Map 01" rattling

o o

Cy!inder·to--pistOncleannc:e e.cesaiv,.Cauoedbyirnproper asaembiy.lnspectandOY9fhauitop-eonc:lparts(Chapler2). Comec~ng rod b«It. C8used by over--.ing. trying to start a badlyflooded .ngineorfrorning""ti ng a lo<eOgn~"lothe

combustion charnt:>er. Replace the danaged paris (Chapter 2). Piston pin or piston pin txn worn 01 Miled frorn wear or lack of lubriealion. Aeplacedanaged pariS {CIIapter 2). Piston rlr.g(s) worn. broken Olsticklng . Overhaul the top-end (Cha~er2)

Piston....a.ndamage..Uat.l8llyfrorn*lecll(Chaprer2). Eng!neoil"",,"Iow.InI!>eCl!Qr'-"orolherproblamcausingk:>w 01 Ie .... ar.d add reconmanded oil (Chaptet 1).

O Eogineoilv~IooIow.Veryold . "",jnoilor""improper

wllight 01 oil used in Ih& engine. Change to corracl oil (Chapt&rl). causing oi"op in oil

[) Camshaft or)oo.mals worn. Excessive _

~sura.Replacecarnandlor/cyllnderhaad.AbnormaJ_

o

OOUIdbecausadbyoils'-'"ationaltMghrpmfromlOwoille..... or Improperwalgh! or type 01 oil (CIIapterl~ Crankshaft and/or bealill\lS worn. Same problems .. paraograph •

ClllK:k .-.::l replac:lcrankshaftandlorbeetinge(ChaplM2).

Electrlcll/ aptem

o o

Oipressur. s w~chdefactjve.Chacklh.swildlaccordinglolha procedur.;"Chapter8.RepI_~~~ .. det""'MI. Oilp«ed wiring (Chapter 8)

Fault Finding

REF.37

11 Excessive exhaust smoke Whltllamolre

o

D

o o

Pittonolr1ngwom.Th.ringmayt..~Otdarnaged,causing

oIIfTom1hectarln bUld-up Inlhacornbusl!on chambarandonlhepislOOCfOWO. lf tNs ls lha case lhe cylinder head allould be ,emoved and the deposits removed. NOle Ihal ~~~.::.,ca,:"bu'::UP leu li~ery wlth

..

Checking battery open-ecorr..::t pair 01 wlrH. Cootlnuity {low or no mNS,,,.bIe reelatance·Ool'msjlhouldbelndieatedwilh the tw itCh ON and no continuity (htvh reelatance)wjthltQfF 3 Not. th.tth. pollrlty 01 tha test probel doesn't mall ... lor continuity d>oecks

.... made

-Mth1he"",,","OFF.

• ,.. . . .t«y~.~disconrwd 1hebfltterynegatNe!·....jlNd belor.maklng checka. parUcuIIo~y il ignilioo switch checka .... Deingmadlt.

:,~.U:!:. :=~~~::~::~ :;:~;:: OlIOnltyf..j.Touc~the'meterprobeSt~her and ch..::~ trnot ....1... reads z ...o; wh«a n..::_ry.dlu.tt~amet ... .., that lt"ad.

and connecting a mat... or continuity testlr "::r"" both ends of the wire ,... Itlu.· 1ratIon 11 ). 2 Contino.OIy(k7worno resistance· 0 oIImaj thouId bI Indicated II the ..... It (IOOCI. II no ~~!1.'reelatanca)ilshown, ~

COfflPOIlIOlIltblingehecked. •

Att ... UIIng .mII....

llways.wileh~OfF

to_~bltlery.

Switch checks I II.sw!Ich.atllUlt.tracaits~""to

the wIrin>g eon....:t ...... Sepa"te the' wi" ~....clQper;llhemlorser:uity_

condi1Ion.AbulId-upofdiflorcorroeionhar • wiI..-tlilctlybllhacauseoflhl~·

:~~and8pp1y'Watard i$potrSllntsuch

2 II using a leSI met ... , III the mel. to tile ohma. 10 -.clla.rId conn..::1 its probel ..::ro. . the wi,.. I,om tile switch , ... Illultratlonlj.SimpI&ONIOfFtypeswttchM. oueh .. br .... NghI .wtta-,on/yha.... two

4 Acontlnultyt_terorlNtterylnd bulb circuit The retationsnip belwMf> cytinOwuwallye' pnone~.=~~I~~

ComOOIlion
M :~:'J~~'rlngs~the "".lnt""..,clt-t... {MF)b. tt..-y A_led

aIIY Up . nd

electric curTanI."""C_ . lMnbdl_.

p

~oIlhelyre.l.essrasistant l 0traad

A thin strip 01 ~IS~C thread. Ivailabieindlft.ent alz.lS.usedfOf""",ouriog c~.Fof.....-r()lI •• otrIpofl'lul~ iI

laid acrou . bearlng)oumal. The pan. . . . • ...."I>ed and dismantled; tn. width ollhe cru$l\odSirlpindic".. thlclur. noebet_

~=:.c.o.:::-knock.~ A _ of a ~oI""oiIwith,oingIevllcoslty.eg M _k A~---""'l.niIlinkirogtlle

swlngatmor~'"'-to""'lrame.

""",Abbr1Mationfor"-perhcu. MuIt ~oiIH.lWlg._~ .... (eg 10W40). TheW Oland. IorWinler,lhusIM

=~F~:::=:t: ,.0".

capability 10,.,."...........

.,.."..m and

,";stance. Some met .... ,Iso lr>eorpaa' l • eonIHJitytest.. arod_

N

:~:,. ~~nllt\a:~::;":t~ c~

~ofunc.ged_"_canbeloond

.ea,

on some engines. Commonly Uled In ..... pension·WOcaIioo • • ndlntwo-.lrolpfISSedwhenin iheunlootdeea_.Pre!oed can be applied byOU. apacero< mechaniCat

...

~

Premix Themelt>odolengl ... lubrlClitionon old lr l"'C- alrok.englnH. EngI""~l smlxed

"-

~ \~~'Z'=~.....:~r&dlO;t~~~ ~clrWlOoecripIionollhe(!riye!n)mlhe craf"O<sllafl~oiIMclutcll . Uaudyby_o\inlliquideooleder-og;n.. Rake Aleatureol-"'l!Oeometr)r-the..-.gle 01 1he-"'l!Ile/Idin,eIItionW1hII-.ertic8ll_ .... lratIonj.

REF-46

Technical Terms Explained

= = ::~

~ ~ac:..~a~':. !i~~:I~:~~ ::!t0rojT~i~ :i~mt~~~j~~

V

NecHsitatH tt\e use 01 oversize piston and rir'igs.

p&'Isofairto t partol luei Sulphuric aeid The liquid (electro/yle) used in a

Vacuum gaugee Cklck-type gauges lor measuring intake Ifact vacuum. Used lor

Rebound damping A means of controlling the osci!ation 01 a suspension uni1 spring after ~ has been compressed. Resist' the spring's natu.al

lead-acid battery. Poi!lO ~~~~"~":oon;:~~~~~-:huto;

~:.a:;e:I~~int!~~~~;;y=j:mmonIY

T

;S::~~YS~~~~::nd':X=I:"~ c;:

Tepered-rolle rbearing Tape<ed in_r3enthe vaM! is dosed.

;::: =~~~~~sf;:::~n~;I:f ~':.na:;~

=~s !:;':~,,:!~,,;:~:~r;cal :I:~:';;i:o:;':rod and rocker a.m. Also =::if~~::=~~i~~seat

RON (Re_ rchOctllne NumberJ A measure 01 afuotl·s resistan-Md-S o ll

sw!ngann - So' •• $o15 _ · 6-19 ~tn.bBII.. ·6· 15

- "27, 6" .

~~·~.i8'8 mast.-cylinder-606,6' 12 pa
Index

C

Cables· j ' IS, I OZO choke - l o21,3 0 14 cJutcll · 2oS4 speedometer-Soil throttle-l o2O,3- IS Ca~pers · 603, 609 Camshetts endfollowers - 2015

chainandblaOes - 20 15 chaintensiooer·2 0 11 Capacitles _ , o:?, ' 03 CartIunrttors _' ' 10,l '1 9,3 o S,3 0 7,3 o 9,3 o 10 heat9l' system· So19 eentrestand ·S· 4 Chaln _OoW,, 02, j o7.1 . t3.S o2. So16,REFoI6 guard - 7-2

Charglng systen'1 _So27 Chemlcals.- AEFo21 Chokecable ·, o21,3 0 14 CIutch -2 ot etseq

cabie·2 0 34 check - "12 probIems-AEFo34 swttch _ Son

Componenttocatlons- , . 6 Compreulon chect! · ' °28 Conneetlngrode - 20 47 bås-2045 Contlnuity- REFo40

Conv_ 1on laetors - REFo 20 Crankease -2 043,2o44

C ...... k. han - 2·45 Cush drt ve rubbers - 5' 18 Cylinclerbloc k -2025 Cylloo.head - 2019, 2o21 nutstightntlS5check _ lo23

o

cnnytp,.-rlde)eIHK:kI- a.l 0

Dirn.nsions - REFo, Dlsc - So t ,S_S,Sol! DrMchain -()o 10, " 2, "7, ' . 13, 5· 2, 5·1 6 guard - 7- 2 o.tv.llne noise · REF' 36

E

Earth - REF o 42 EJectI1cal fllUltfind il'l9 -So3 , REFo38 Eleel1fcal s ysf.m · So l e lseq

Enfl/ne -2 o, .tseq eompression_ ,o 28, REFo39 disassemblyandreassembly- 209

F Fal,l/tflndlng - REF· 30

8qlllpmenl - REf · 39 Finllldrive -S· lefseq

FIOlIt height- 3'I,3' 10 FluIdI -l · 2. 1·3 Footrnts - 5' 3 Fork oH - l' 3, 1·25, 1' 27,5·1 ForkI - S' S,S'6

Frame - Sol etseq noise -RE F0 36 nllmber - Oog

Front mlldguard - 7 0 2 FuelgllUge -S ol 2 F.... l hoIe -l · 27 F....I .. ~ - 3 0 1 . 3 0 12 $l!flder - Bol B

Fuel system -301 etseq check - l o 22 Fuel tank - 3' 3,3' 4 Fueltap _3 04 Fuses - Bol.B 04

G

Gnkets - REFo 17

GllUa-s- B' 11 Gearcllllnglngproblem. -REF o 35 a.... 1_ - S· 3 Gellrcllllnge mecllllniam - 2035 GlossaryoftenTII -REF 043

GnIb_rall _7 0 3

H

Handlaoba"' _,S' 4

..:.::: :--S~;~

ai'n-l 0 2B bulb - So6 Hom _ B0 21 Ho_ - 6'14, REFo l9 HT coIl. _4 0 1,4o 2

Identltlcatlon nllmben! - {)og 1d.. tu.II... miKl .... lldjuetment -3· S Idlespeed - I'2, l' IO, I ' 19 kllalteductiongear (startermotOf) -2 0 36 Ignltioncontrol ... nIt - 4 oS IgnItion HT colls - 4* I , 40 2 ignition n'IIIIn (kay) . wltch -BoI 4

Ooesn'\slart-REF ' 29

~/tionSYSIWn _ 4 0 Ietseq

noise· REFo35

Ignltiontiming- 4° I, 4° 6

number - Gog

Indlcators _BoB,B09

00 - 1· 12. 1· 21 le\tel-O· lO

bulbs - B· B Instruments - SOl I bulbs - Bol 3 cluster - SOlO IntTOdllction -0 0 4

Evaporationcontrol . ystem - l . l1 . 3· 17 E.rchsust.yst.-n- 3· 1 etseq

Index

J

Jet alles - 302 JunctiOnbox-So\1

L

~r.272029

~~~.~1' 14.8'8

Poor,*,dlingor.~MIty_REF.37

switcl>M - s·g $toraae - REf"27 Suml' - 2'40 Suspenaion - Ool0,5' 1elseq

Poorrunning -REFo32.REFo33 f'ulMlI''......tor"coll _4 01, 403

R

Lega'chKks - Ool1

Rare_ -7oa

LeWlI1lIl"-REFo13 ~_1 " 6.5.5

::~::~~;5"2,5" 3

UghtIng~-8'5

Rurwheel coupIInwrubb«omelW - S' 12 T.~ light- S08 !>.llb_S· ] T.'I ~ - 7.3

TKhnicaI_ .xplained-REF'43

~~R":F~- 1 '20,3.t3 Torq ... - REF. 13

~;02' 1eiseq shalls - 2' 49,2oSO

T,:,~~,~S'S' 8-9

s.NRU-REF o 17

T)'f'N-00 12,I .tS,6>I.tseq

Sen -Io,

a...ctor drum end 1DfI....tIen - S.,2.S·,3 Short_drcult_REFo42 SkM,,,,neIs-7 0 2

::rnd'":'~'~ aos switch-SotS SparoopartS - Oog

Sparkplugl - ,02,l-9 ~'8'11

=~;:1~'16 StarI_c!uWh-2'3I\ StarI_motOl-8022, S.24 StarI_rwlay-8022

P

St¥tin.g~·AEF·31

PaIU~ng)·()09

=k~~-5' 13,5' 14

Swingarm-5' 14, 5'15 pM>! and b8amg l...oocalion - 1' 25 SWltc:hes - S-9,S' 13.S.t4, S·15,S' 1S,S'17

S:!.~:t2

~ _REF.34

"-

Kawasaki ZR550 and 750 Zephyr Fours '90 to '97

Haynes Kawasaki Zx900, 1000 & 1100 Liquid-Cooled Fours 1983-97 (Haynes Motorcycle Repair Manuals)

Waiting for the Zephyr

Waiting for the Zephyr

Waiting for the Zephyr

Waiting for the Zephyr

Upgrading to Fortran 90

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

Plätzchen, Konfekt und Petits fours

97)

97)

97)

97)

97)

Kawasaki GPX250 Ninja250R Service Manual

Kawasaki ZR550 and 750 Zephyr Fours '90 to '97

Haynes Kawasaki Zx900, 1000 & 1100 Liquid-Cooled Fours 1983-97 (Haynes Motorcycle Repair Manuals)

Waiting for the Zephyr

Waiting for the Zephyr

Waiting for the Zephyr

Waiting for the Zephyr

Upgrading to Fortran 90

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

97)

Plätzchen, Konfekt und Petits fours

97)

97)

97)

97)

97)

Kawasaki GPX250 Ninja250R Service Manual

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