Kawasaki ZR550 and 750 Zephyr Fours '90 to '97

o Check the air suction vaIYe (US models only)

O ~ion~,~~controI>(EVAP) system(C&Iifomla~ontyI~7).

o Check and empty the.fIIt.- (bin ~

(SectIon 8). D Change the engjpe 011 (Sction 9). Check the operatIOn of the dutch(SeCtlorl 10).'f Check for drive cheIn wear and aINIch ,,: (Section"). . . Ch8ck the brake peds for wear (Sectiort 12): Check the operation of the brakes, and1rlt 1Iukt leakage (Section 13). 4;'" ~ Check the steering head beIring ~

o o o o o (Sectloo 14).

• <'. D Check the tyre and wheel ocincIIIon. arid the tyfe tread depth ($ection 15). Check and lubricate the stands,"""" pivots and cables (SectIoo 16).

o

Non-scheduled maintenance

rQChecktheheadllghtaim(SectIon~7).

JW ChecK the wheel bearincs (SectIon 38).

U

Check the cylinder compr8IISion (Section 39).

10 Check the engine 011 Pf8SSUI'8 (SectIon 40).

Component locations on light-nand side

I Rearbtal!tlf/uidffJUHVOtr

5 Front forl!SNls

2a.1t8t)'

681a1rapad$

3Fronr.brakafluid~

7~oiI~pJug

4 Throrrlacsblaupf»fadjuster

8 Enginaoil/evelwindow

9 £ngineoiJfillffrcsp 10Clutchcabialoweradjuster II AirfilterdrainraS8fVOlr

12 Rearbtalrallghr switchllld pedalheighrad/U$ r8l'

~"'""""'"

Component locations on left-hand side I Clulchcableupf»f&1juster 2 Steeringheadbearings 3 SpMcplugsandvaives

4 Fueltapfillar

7 DriWJchaintldjustars

5 Thromes/OpSCt'ttWPdiaspaadJ 8 DriWJchaIn 6 /lJrNter

9

SwingamJpNol~

10 £ngineoilNter II EngineoildnJlnplug

12 Frontbtakflpads

Maintenance & servicing

1' 7

Introduction , ThisChapteriadesignedtohelpthehome

h a"e~verp8<1ormedanyma l n t enanceon

mllCh anic maintain hislhllf motoreyd. l or safety. """"""'y, klng lile arid peak

:~t~.:r)'~,,~aYi~C~~~~ S!!~:t '~~~~~::

performance.

ptocedurestoenSll,e that nothi"llimpol1an'

2 Oecldlng w here to Slart or plug InlQ l h" routine ma inlenance schedule depends on several factors. If the warra nty pe,iodon

IS overlooked . If you have just had a major eng ineove
your motorcycle hos just ex pired,and il it

Ihe ma
has been ma inta ined according to Iha warranty standa ,ds, you may want to pick

knowled g" of 118 history or maintenance

up routioe maintenance asil coiocideswUh th.. ""xt mile8ge Of calendar inter;.1. If you haveQwnOO tile machine l or some lime but

~~:nc':t~~~oin~~et~~'~a~n~;~~~~~It~~~~:~I:

'!lCord,

yo~

maydesir. to co mbine a ll the

3 Belore beg inning any malnlenance Of repai" the machine should be cleaned thoroughly, especially arournlthe oil filter, sp a r~ plugs, valve cover, side pane ls, carbu, el1ors , etc, Cleaning will help ensure that dirt does not C'lfIOticed, 4 Cena in maintena nce in formation 15 sometimes ptinted on cSecafs attached to the mOIQrCycle. If lhe Inlormallon on Ir.e decals

~::::al::':' 'tt;:..t ~~ded h8<e, use Ihe

Every 200 miles (300 km) - ZR550 B & ZR750 C Every 400 miles (600 km) - ZR750 D might

1 DriYechain cleaning and lubrication

damag a

the

Intem .. '

se.. ling

~~ =:=:~~;~~:~=-:i IIdou, the O.rlngslnfhe chalnrollers

t Place Ihe mac hine on 115 centre sland (wllMefil100j,orsupport lhemachineonan oodlarystand so \hal lherearwhMtf ", off lhe !I'(lUnd.R<>tale the back wheefwhilslcleaning :.,~.IU brfCaling lhe Chain loltCCessalll he

2 Wash Ihe chaW, in paraffOn(k"""""",),lhen wipe il ot! and aHow il to dry, ~sin g compressed ai, Ilavailable.lflhe cha in is

7~~e~~~~rn:'~~1 :=~m;:":~~nlr: paraff-.n (see Chapter 5) C .. ullon: Don't use

petrol {gnoline}, , olvent or otha, cleaning fluid, which

~":!~~~atetheChaOnisalter

lhe molorcycle has been ridden,as when the chain Is warm the lub
=:::WHn

the spe<:llled lub~can l (..... Specification. attha beginning of the Cha plerj 10 Ihe a,ea where Ihe side pl ates

.. Apply

overtap·not I O l hemldd~o l lhe r oll8fs (_

iliustratlon). AtIerapplyinglhe lubrfcanl,1et1! s oak in fo< a tew minutes belore wiping otl Myexces.s. Ca utiort' If you use a" aet'O.!lol dr/ve c/lalrt lubricanl,malce,u,.. it is marlredn being

lA AppIyIhe specifled lubricant to Ihe

0""r1aplMltw.,..., u.._pfale5

Every 500 miles (800 km) - ZR550 B & ZR750 C Every 600 miles (1000 km) - ZR750 D 2

~~~~:~;ee~ay check ~

CO"""

""

1 A neglecl ftddtiWIchain won'llasl long IWld

can quiCkly damege II>e sprockelS. Routine chain adiuStment will &nSUre maximum chain andsprocketl~
2 To clleck Ihe chain. shift lhe lransmission

:~7.':a~:~~~the'"'t:::'c~;~~ pos~ionedw~hthelighles t

point 81 the centre

o!itsbottomrun , Ihen~lhemacl'lineon

i«Iaidestar"ld. Make s ure that lhe adjuster Is On

lhesameposi~onon each side relatil'e 10 the CU\ .QU\lnlheswingarm 3 Mea sure lhe amoonl 01 Ireepfay on Ihe chain' s bottom run, al a point midway belween the two s prockels,lhen compafe you,meaSU'emMlt 10 the value lisled in Ihls Chaple,'s Specifications I..e illustration)

!'...~~:,:!!':,~~rar:!I::=.rt=~ c an be checked ; do th is .. V8
2,3 Measuringdrhe chainf,eep!ay

' " Maintenance & servicing

ridden. If the chain i•• tlll tight in the same arM, ~ may bft damaged ",.worn. Because a

light

or

kinked chai n can damage the

t ~ou t putshahbearlng , ~'$aflOOd ideato,otpI_~

Adjustment 4 Rotate the rea, wheel oMil the cha in is positiorledwijhllletigh1eslpoir1lal thecentra

the oth", adj uster l u"," 35 Well. FoUow i.,..

1 1lthe,e is a dise repaocy in Ihe cha in

chain adju.t men!, make .ure thai each adjusW Is In lhe same pooitlon re!aliv9 to the CuH)ullneachsideottheswlngarm js•• Illustration). It Is important that theume notch 00 each adjuSter aligns w ith Ihe

adjustorpo. ilions, adjust one oT H>e cha in adjustars so thai It. position is . xacl ly IIlII

swiogatmcut·out;~oot.\f>erear_wmbe

10rque a,rn nulS to Ihe specilled torque setfug l..... ibuslfation. )

out of

alignment w~hthefront.

aame as the otl>ef. Cl\ecklhe chainlreepjay udescribedalxlveandre&djustil neceesary 8 nghten the adjuste
~~=I\IIl.thenplace,t>emachineOt1

5 Slacken the chain adjusteswingarm""""lyuntil tt>eamount

~h:=al~ s=~:~da~:'7t,~e~~::O 0~1 :~ t>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<:le·stooikitWhichfsstor&dUr.der the

unscrew the plugslrom the cy1 inder head (see

: ; :,:'i, ~t~:~~~~I~~ ~e~

it wil l then be easy to kleotify the troublesome

permittoo.providedyouclean tileplugsw~ha

cylinder. 5 Inspe<:tth&elec1rooesfO(wear. Both the

high Rash-po;ntsof\oentalterwards.

centre and side electrodes should have

8 Beioreinstalling tile plugs. make sure Ihey

square edges and the side electrode should be 01 uniform thickness. Look lor excessive

are tile correct typear.d ileat range and check the gap betWe&!l the etecl rodes (they arenol pr&-seton new plugs). ForbeSI results. use a w ire-type gauge rather Ihan a flat (Ieeler) gaugetocheckthegap(seeiUustralion s). Compare the gap to that Specifioo ar.d adjust as ne<:essary.i!the gap muSIbeadjust&d, bend the side electrode on ly and be very careful not to chip or crack the insulalor nose (5etl illllstration). Makesorethewasherisin place beforeiostalling ooch plug 9 Since the cylinder head is made of aluminium. which is soft and easily damaged.

deposits and evidence 01 a cracked or 2 Remove the seat (see Chapter 7) and disconnect the batlerynegalive(-j lead. 3 Clean the area arOllnd th e plug caps to prevenl any dirt laliing Into the spark plug channels 4 Check Ihat the cylinderlocaHon is mark&d on each plug lead. then pull the spark plug cap off each spark plug (see illustration). Using either the plug removing 1001 supplied in the bike's toolkit ora socket typawreoch.

inSlJlalor). If in doubt conceming theconditio
the expeoseis min imal. 7 Cleaning sparl< plugs by sandblasting Is

chipped insulator arollfld the centra electrode

Compare your spar1< plugs 10 Ihe colour sparlr. plug read ing chart on the Inside resl cover. Check the threads, the washer and the ceramic insulator body for cracks and other damage

6 II lhe elactrodes are nol excessively worn. and if the deposits can be easily removed with

awirebrush,theplugscanbere-gappedand re-used

3.4aPulioffthesparl
ftf no cracks or chips are vis
. .• lhenunscrewthespar1
'.'0 Maintenance & servicing reedOOlders,aod thel>olders!hernselves, for any si9"" 01 damage or deterloration. Any CIWboo deposits Of other foreign particles cao t>eclearMKIoltusingahlghllaoh-polni

.,MOO

threetd the plugslnl0 the heads by haod {see ~ Iu stno tion) . Once the plugs are lingeHight. lhejobcan bllliofshedwit hlhetoolsu~ied o, a. ()ck "t.T ~ ht "nt Ms pa", pl"9s t oth "

=iedtOfClLJeSetting;donotOvet-lighten

~,repeatt headjuslmen tproeed ,,",.

5 II . smoolh.steady idle CM·tbe ac:hOevtid. the 1...... lIa ir mixlure may be incorrecl (s. . Chapt"" 3) or Ih. c ~bur. llor l may need synchronising (seeSeetion 6).Qn U$modeIs ,

upperand~gasketsandreplace lhem lf

ehee klhe.~sllClionvalves(_Seclion4)

= ? ; he Vft!\leD5!lemblieswiththelr gaskets (550 moo:Iels). making Sl.re the

3.9Threadthepluginas lar aspossibie

"Snap the throtl~ OIMI'Ilnd Ihut a f. w tlm ~s , lhen .eche<:k the Idle speed. II

ther"is anydoubtabovttheircooditiorl.OI'l 550 modelS. also Check the cond~ion of the

soIYenI.~ th.'Mdva/vtlilSsemb'esW

6 CarburettOf"S-

m;c~O~i~~~R750 C)

projectionOOeacnvaMll'o:liclef~up.then r.stallIheCOYer.l_IighI""thebolts~""""Y.

5 Idle speed check and adjustment (ZR550BandZR750C)

~ ~

1 The Idle speed Ihould be cl>eeked Ind

adjustedbeloreal'ld af1er theCllirbu"et1orsare lynch.oniMd (balanced) and when il is

.& :1?~~;~~~:!~'li:

~tem. o:,°t...:'.::::::::, ::.e:,";,,::::: or-b8re/ightbulb......"heworll erN. IMd don·t ....ork Ina "a"",,1 "'h.... . natural "as.lypeappllancai.",....... t.lfyou.pill

::~Yu.:~leh::'m~: :.:.tt!~~~ ~;iE!:lr:;,~:~~:~;::~~:~~

10 Reconoect the aparl< plug capS. maki""

Su'e they Sre secu.ely connected to the eorrecteylinder.Connectthebatlery negative Hleadandinstallthe"",,1.

4 Alrsuctlonvalvescheck (US models)

clearances and SP3rk pluo oaps a •• correct. Also.tum lhehandlebarsback-and·lorthand _ ~theidlespeedchaoges asltl"isdooe.

~I'm, ....... ufatygl8ssesandhave a ''''' utlngulshM s"ltablafor- a ClassBtypatire (fI~ablel/q"IdsIOllhend.

conuOl ollhl bike. Be su.e 10 correct IhlS problem beIofa proceeding 2 Theengin.shouldbealnonnal operating tet'fl!)!tl'D1ure. wtIIeh is uwatly reached aftar 10

" a",,1 'akl-offpoin ll on the In la~1 manifold•. Do nOI . 'Iow I xha". ' ga ... tobulld"plnlh. worl< _ ; .ith.,. partonn t"~ chack o"tlld. or "s. a n

~f=~~~~~::=·n=: .& :i~~~a:=~i!

~ :::.,~~~e:.~:':ua;:$::~'.:a;:!: ~x~~:"~~:==~:'IS Simp!), ~

the

orsuppor1~uptlghl llSing.n auxlli arys tand.

~Dladju5linglhecll/I)UM!l orsoolhe)l

1 RemoYethe lueltank rMflChApler3)

and make aura !he transm"sioo is in neutral. 3 Wi'h!heengi""ldjing ••dius t !held l~speed

2 Unscrew the toUf boU s securing each

by turning the th,olUa alop acraw In Or out

:::v:~o~:~()r~Va!V~h~~~,:

lmtiltheidl"'peedl isledinlhi.Chapter·s $peelflcsIO)n.fsobtalned.Tl\ethrotllestop scraw I. located on lhe left· hal'ld aI'Id of the ca.bur"ttorJ "" 550 mod" ... end undwl'" carburettorslnth8 mlddlaon750mocIefs {... IHustrallons).

pass lhe"me amount ol'ueV.'r milcture to eachcylil'lder. This is dona by meas .......... lhe vacuum producad ill eaCh eytinder Carborettors lhat araDnilation will ,esult In dooraa$ed luel mileaoe, irler&a$edengnelempera.tura,lesslhankleal thronle response Sr>d hlgharYlbrationlevals, Beloreaynchrooieing thecarburettGl'l.maka va1vecleanlne ...... proper1y sat .

lI$SIIITl~in.noting_hwayupth8yf~ .

3 Check the roods for crecks . .... arpa9l' and

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

.......

.....--~,....,

Maintenance & servicing "" right-hand carburettorsjoos. 3 and 4)uslng the centre synchronising screw. When an the earbIJrellQrssresynchronised, openand close the throttle quickly 10 senle lhe tlnkage. and reche<:k t!le gauge llHIdings, readjusling if

n.ecessary 11 When

the

adjustmen t

Is

comp lltte,

recheck the V8Cuum readings,lhen adjust the idle speed by luming the throUieSlop SCfSW until the Idle speed Usta
and lhetake-off blanking caps or hoses, Of EVAP and suction vatve hoses onto the carburett~.

12 Detach the temporary '1,1&1 supply and install the fuel tank (see Chapter 3).

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 spe<;ial instrumants, most ewners leave the lask Ie a Kawasakidealer. 3 Start the eng ine aod let it run ""t~it reaches normalcperatingtemperat.... e. thenshut~elf. 4 Aemove thefllBl tank (see Chapler3) 5 Oiscoonect the fool tap vacuum hose and remove the blanking caps or hoses (UK models),or EVAP and suction valve hoses or blanking caps as appropriate (US and Calilcmia medels) frem the take-elf stubs on the carburettors (see iUu strationj. Mak e a ncteof which hoses fit where 6 Connect the gauge hoses to the take-oil adapters. Make sure there sre no air leaks as false read ings will result. 7 Arrange a temporary luel supply. either by using a small temporary lank or by using extra

loog fuel pipes 10 Ih-e now remote fuel tank. Alternatively. position the tank on a suitable base on the motorcyc le. taking care not to scratch any paintwork. and making sure that the tank is safely aJld seeuraly supported 6 Start the engine and let it Idle. If the gauges are !iltedwith damping adjustmen1.setlhisso that the needle Hutter is just aliminated but so Ihattheycanslill respondto smallchangesin pressure. 9 The vacwm readings lor all of Ihe cylinders shculd be th-e same. If the vacUIJm readings vwy. proceed as follows. 10 Thecarburettorsaraadjustedbylumir.g the synchronising screws situaled in-between eachcarbl.lrettor. in thethrottielinkage(see illustratioo6..Sj. NOle: Do nolpreSS down on !he screws whiisl 8diustlng them. olhelWisea false reading wlli be oblain&d, First synchronise lt1e OUler leltcarburettor {no.l ) IO the Inner left carburetlor {no. 2)unli l the r&adingSare Ih& same. Then synctvonisethe outerrighl CQrburet!or{oo. 4) to the Innerrighl carbureltor(no. 3) . Finally synchronise the leU"hand carooretlors {nes. 1 and 2) to the

1 Visua lly Inspect aM the EVAP system hoses for kinks and s~~s and any other damag& or de!erioraliOf1 . Make sure Ihat the hoses are securelycomectad with a c lamp 00 esch&nd. Replace any hoses Ihat are damaged or deteriorated. See Chapter 3 lor further "formationandadiagramoflhe~l>i'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

Maintenance & servicing

'.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
u-w. _ _ _ bedIKIIlId. InI"'OU,III.clutclllla~ing

10 Clutch-check

~';oo:I~=, ~~'.U;~ ~ ::::~~-:.: ~..."...~

moneyontn.dIH..... nc .. incOlllbelwe«ol goodoiland'eMa"oiIwon'l payotlHtl'lol

.-.gInOI . ~. NoIe: rr..o/I_WOukJ 1 TheoklDildraioedlrornlhetnglnecannoc be ,.uNd end II\ouId be diaposed 01 2 Beto'I • ....-ywcondor~

K I . . . ,...,Ind... lhal Ih
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

Maintenance & servicing

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$lme<1thas bel!l1taken up al lhe lever, reset the adjuster 10 give Ihe maximum amount offreep lay,lhen set the corr9Ct amounl 01 freepillyusing the adjuster at the clutch end of the cable. Subsequent adjustmen1SC<'lnthen bematleu$ing the lever adjusterOl1iy. 4 Toadjusl the freeptayat thecMch, lo<:lsen the locknuts and move the adjuster unti l the requiredarn()l..Oll ol f,eeplay isobtair>ed,then Ilghten the IockrnJts againsl the bracket (see

Ilh. stralion). To increase freeplay, move the

adjuste' dowll III the bracket . To reduce !reepay, pull thfI adjusler up In lhebracket. 5 Theclulch lever has a Spall adjuster which atters the distallce of the lever 'rom the handlebar (see IIlu 9Irat loll). Pull the lever away lrom the handlebar and tum the adjuster dial until the seltir.g which best s u~s t he rider lsoblallled.TherearefoveposltlollS.AlIglllhe number lor Ihe setting requ ired w ith Ihe triar.gu!ar mark on the levefbrackel.

11 0rivechaln wear and slretch

check

"'3

measured end compared 10 the stretch l im~ spec ified al the beginning of Ihe Chapter. Place the mach ille Oil Its sl(lestand and remove the chaill guard (see Chapter 7). then hang a 10 kg (22 Ib)welght lrom lhe botIom nm 01 Ihe ch ain. Mnsure along Ihe top run Ihe lenglhof21 pins (from l he centre 01 l he 1st pin to the cenlre of the 21st pill) and compare the result w ith Ihe service limit speeifiedal thebeginningolttleChapler ( _ ill ustrat ion). ROlate l he rearwheul so that

~ :~er~~==~ ~':~:~i~ t~~ =~;~~:: ~ ::t~~i~ ~ ~:::c:!:~~:I:;:~

1 Check Ihe enlire lenglh of the chain lor damaged rollers, loose links and pins and l eplace Ihe chain If damage Is found. If the chain has reached the er>d oIits oojuslmer>I,it m U$ t bere~aced.

2 The amOtJnt 01 c hain streich call be

andsproclcetsasa~et.

3 Check the teeth on the &rIgine sprocket and rear wheel sprocket lor wear (see Chapter 5). 41 nspeclthedrivecha lllsiideron ihe swingann lor excessive wear and replace ~ II (see Chapter 5)

necessary

11.2 Measure the distance betwe«l the l s i detenn i... ctoltin stretch

and21st~ns

to

12 Brake pad$ - wear check

13 Ek'akesystem -check

~~

c,acksln thelloses (see lliustration) ,llthe ~orpedalisspongy,_lhebrakes(_ Chapt... 6),

!tZ~:t'::;':~':s~::'~~==s: handl.t>a'(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 lhereM
Brake light

::7~~r;

t:: =~no:S: ~~=,6J

the thickness of the material remaining is t mmor less,lhe pads must be replaced, Nole , Some alter-marl<el pads mey u •• different indic.tors fo r~os. on the origin.1 9qVipmen1 pads shown 2 ReIer to Chapte< 6 lor detai ls 01 pao;l replacement.

=:':t(:::!=~)~:=::

13.3 Flexlhebrakehoses_checklorcracks, bulgeB Bndleaklng lluid

.5 Make sure Ihe bral<e lillhtoperala. when Il>e 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

Maintenance & servicing

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 thelo<:knut on the master cyl inder pushrod, then tum the pushrod using a spanner on the hex at the top of Ihe rod until the pedal is at the correct height (see illustration). 8 If access to the pushrodis too reslr\ctecl, remove the footrest bfacket mounting bolts anddetachthebrakelightsw~chspring from

l he pe(lal. lhendraw the bracket away from theframe,takingC8renot lotwistorstr~nthe

master cylinder hoses. On completion tighten

1·15

head bearings will be fe lt aslronHo-rear

Check 2 Place the motorcycle on its centre stand . Raise tile front wheel off tile ground e~her by Ilaving an assistant push down 00 tt>er&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 ~for8CC
(seeChapt6r5j.AisosJackenlheboltS6CUring me headlight suppor1 t.ama tolhe bot!om yo!<e.locatedbehindtheb
II Usiflg8suitabklC·spannerOfdriftlocated inooeollheflOlchesinlheadju.lerrin<;l locknut, slack"" the locknut sl~hlly (.ea lIIu. trallon) . Now inltlalty slacken. then tighten or slacken/urlher lhe adiuSter mg as requi,ed until allffeeplay In Ihe torl<s is removed. yellhe steering is able 10 move l,eeIy t,om side 10 side. The object fs 1,,"1 Ihe adjusler ring so that lhe t>earings are under a very lighl k>ading, just enough to remove any Ir.... play. T~hten lhe loclcnut agalnsttheadjU$terringlinger.Ughton1y Caulk",: Take grea l care nOI 10 apply

nolchiM5S,lhejI wiR have 10 be removed lor lnspecli(ln orr$pacerner1t (see Chapter5) 8Wjjh the bearings correctly adjusted. tighlenlh.st _lngstern bo4l and lhe lorI< clamp bolts to the torque sett.-.gs specilledat the beginning ol l he Chaplef. NOlI: Depending on II!4 loolsav8ilable, it m.oy be I">9CeS$AI)'I0diSPlacelhehand/eblJf"sinorr:l$r

or

15 Wheels and tyJes · check

'"

1 S
~

2 The c ast wheels used on all "xc"pt ZR750 Dmod,,~ a,e "';r1uallyma inlenance

periodicallytoensu'.sa1.andtroobl.. operation. 2 The lootrests. clutch and b'ake levefs. bfake pedal. gearshift lever Iirlkage and stand p;votsshould be lubricat&dlrequenlly.In orderlorthelubricantlobeappliedwher&it wiHdolhemostgoOO.lhecomponent*"",1d bedisassernbled. However. Hchain and cable lubricant is being used. il can t>e appl;ed to the p
1...... but Ih.y should t>ek"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 ane',lIackenthe locknul,lI>enadjusl

16 Stands, (ever pivotsaod cables -lubrication

ab<Weandre-adjusl~necessary

~ malu refa j/u reoflhebearings.

if the.e is any binding • • oughness

~_w theh~pofawhe&tbuildinoexpertif!hi S i S

10prrmrJeenoogll~forasockellln<J

/OrqueWf8fICIJonthesteeringstemboll(_ Chap/er5) 9 ChecI
exceuIY'pt'8$wrebecauselhiswlllceu.. 7 Wlhebearingscann<>1 t>eset "P properly. or

with a ,crewdriv", and nota the sound p,oduced . Propeeh;gherpilcl>ed. Unevenlyl""sioned spokM witl promote rim misalignment· see+c

~t:..,~~,:"ad to adjacent spokes which may 4 If you suspecl Illatany 01 the spokes are incorreclly tansion&d. tapaach one lightly

moloroitorlighlgrea.. isbeO:>gused.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"'b
lhecabkowiltt a pressure adapler. or if one is nOlavailabl • . usinglh....I·upshown (..... IlIu~tratlon,). See Chapter 3 for Ih .. chok .. and IhroWecable.emovalprocedu,es.and Chapl ef2lorthectutchcabkl. 4 The.peedomet8fcabklshouldbe.&mOved i_Chapt&r 6) and the lnnercable withdraWfl

Maintenance & servicing from the outer cable and lubrk:aled with moto.oIl or cabfelub<1can\. Do not lubricate

the upper

few

inch" of the cable as the

::~~&I\t may travel up into

1. 17

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

the instrument

,

NipJ)l..

Oil

Plastic bag

~~ca~nd

~suspended

Caution: Be extremely careful when h/l1ldling or worif;ng around the bettery: The electrolyte is ...ry causlic lind an explosive fills (hydrogen} Is given off when

.

Iheblttt~lschllrgir>g.

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<; with distilled water. Do not lISe tap wal er (except in

an emergellCy). and do not overfill. The cell lIoIes are Qu~e small. so II may help to use a clnn plastic 5 qU" ~e bottle with II sm all spoul to add the water. Install the battery cell

caps, l ightening them securely, then In slall the battery.

Q'0

-1QI1y

....toM oil drips

trom

tllr ~nd

16,3b lubricating a cabla with a makeshift h.lnnel and moloroil

Every 6000 miles (10 000 km) or 12 months ZR550 B & ZR750 C Every 7500 miles (12000 km) or 12 months - ZR750 0 enginacanberotateduslnga17mmsocket

18 Valve clearances check and adjustment

~ ~I:;~!~~m~~r~:~r o~~;. ~~~~~,i~;~: ~

2 Aemove the valve cove< (see Chapte<2). Unsc.ew the spe:rk pIu~ to aHow the angina to be Ilmed over easier (see Section 3), 3 Make e chart o. Sketch of all four valve posliions so thai e note of each clearance can ba made 898insl l heralevant valve. 4 Unscrew the bolts se<:uring the pulse generator coil cover 10 the righI -hand side crankcase cover (saa illustration). The

themotorcycleonitscentfestand, selecta high gear and rotate tl\e rear wheel by hand in Its normal direclion of rotation Caution; DO NOT use tlla timing rotor bolt to tllm tile crankshaft - It may snap or strip out. Also be slIre to tum the engine In its normal direction of rotetlon, 5 Rotata thoe ang ina until tha T mark on tha rotor aligns with the s1atlc li ming mark on lhoe crankcase (sse illustrations). At this pOint ei\tl(lrno.l cylil'lder or no. 4 cylinder will beat top dead centra (TOC) on t he compression stroke. Check thoe pOsition 01 Ihe cam IQI)es on no. 1 cylinder. If lhey ara taclng away from

IS,4 The puls8 generator assembly cover is S8(;Ured by two bolls (arrowed)

is.Sa Rotate the engine using a 17 mm socket on the timing rolor he~"

1 The engine must be completely cool for this malnt801anceprocedure,soietthemachlne sli

ovemight beforebegiMing,

8ach olhe., no. 1 ey1 ind8' is at TOC on Ihe compression stroke. If Ihe cam lobes afe facingeachother, Iheiobesonno 4cyli nder w i ~be facl ngawaylromeachol herandno.

4

Is atTDC on the eompression stroke.

6 With no, 1 cy linder at TOC on th e eompresslon slroke.lhe l ollowingvalvescen be checked a) No, 1, intake and 8l1haus/ b) No.2,8xhausl

c). No. 3,inlake 7 With no. 4 cylinder at TOC on the :"':~~:~ slrokll, the foHowing valves caro a) No. 2, inlake b) No. 3, (txhaust c) No.4, Inlake and exhausl

'·'8 Maintenance & servicing

8 InHrt

a IMler gauge of the aame thickness

.,.!he

COft..::1

Spec~icaHons)

valve

c learance

_

_

_ _-

-.,

(see

belw .. e" the cam ban and

loIklwer oleltChvalveandchec . thalil lsa l irm slidlog lit· you should feel a slight drag wtlenyou p<JIlhegaugoec;ut (HtliMuslration).

Il nol,use tr.e IH'argaugntoobtain the aX8ct c learance.

Re-cord

Ihe measlHed

elea<aroc.ton thecrwt. '~ol.,. tlM . ngi"" . o

Ih1l1111. limiogrolor

lumsthrovgh361Y al'>d lhe Tmarlc is once again (:om,<:11)' a ligned. then measure tha va/veclearanceol lheremaini
':~~~~=~measlQd

==E=~==~~~

=~~~~he":.:e~kn.ss 11 SlWnrepiacementt'9QUiresremovaloflhe

c""",halt.(_ChIIpte< 2). Thweisnoneed 10 remove both camshalls H shirTl$ Irom only one s
,,,.,,.,,,,,the

12 Wilh the camshaft removed, Cam IoIlowe.ol the valV
pr!MtheshimOUloflhe topoflheva/Veusing • """,lIscrewdriverand"""",,a~ using a pair oIp1iers r _ muatrationaj

13 The shim aiz•• houkl be stamped on 118 'ace. A$hIm !liza()1 250deno' nalh<:kne$s 01 2.50 Mm. 245 i. 2.45 mm. It I. re<:ommendedlhal lhe shlm is measu..oo 10

~:~ ~~~

:v==j~oJS:-m"::::::~

fTOm 2 .00 mtI"I 10 3.20 mm. 14 Using I he appropmle , him seleclion chart. find ..mere the measured valve cIfi
(sea IIlustratlon sl. Obtain and Install the

~=ns":';~"':~n::~:: ~n~=

shimshoukibalubricated""';thrnotybc\e(Nm disulphideg,easa· th is will also hold II In

,--------------------,

Maintenance & servicing

1.1 9

19 Idle speed - check and

adjustment (ZR750 0) 1 The procedure lor checking and adjusting the Idle speed Is the same as for lhe oth9f models (see Section 5j,

20 Camurettors synchronisation (ZR750 OJ 1 The procedure fOf synchronising the carbu rellOfs is the same liS lor Ihe o ther models (seeSect;oo 6).

21 Airfilter -cleaning

~

~ 1 Remove the fuel tank and II'oe tank bracket (see ChapterS). 2 Unscr!tW the two screws securing theai. filter cove!" to the filler housing (see

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_toerlS
"",""". Ca ,il/o,,: It III , machine Is clHltinually rld<JenmduSlycondilionl,llIe r.tlersllould be cJeanedmore freq<Jltl1t/y.

~. ::~~:~:io~=t~r:nf~~~ cabl" •. nece"si'8 t ing th e r~valoftht carbureUo,.andlnapectlonoflha th,ottla linkage (S
3 With IheIlYOllleOperaling smoothly. check

22 Throttle and choke cable check

~

lheh"oopIayinlhe l w'ostgripandcornparew~h

~

theamountSpecilied l_

iII"s1ration).Htl>e

Throttle cables

21.5 App/y oil to the elem8flt, II\en squ..u It out

1 Mak,su,tt hethrottle gnp rolates"".ily fromfuIJyclos&dtolulJyopenwilhtl>el,oot wheel lumed al various angle •. Tht grip si>ouIdretLmB
22.3 TI>rottlecabielreepiaylsmaasuredln terms 01 twialgrip rotation

Maintenance & servicing ,."

=:()O~er,~YI';o)Correc1.adjUS11he

necesaitating the removal of the carburettors

~~.: ~j:=~~:=n~~~t;:

Cl\apter3).

on the accele,ator cable wt>er& 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 ac<:ess to the cable low6radjuSlers at the carbo.rettor and Adjuslthein-lineadjustersintheacceHlflitor

and decelerator cabl". usir>g Iha aarn .. ~um.lflhecables . tillcan ', be adjusted 10wllhlnsp9C~lcat lo ns, r epl_ ' h9ITI( S "

Chapte<3)

& ~::~i~~~~!2::: s"ouldno rcha ~.tfll_ s, !I"

ca~

may be

roUI~

Inc:orncl/y. CorteCI

Ih;, eondilion before riditlf/ lhe bib. 8 Chec k that th .. IhroW"twistgnpO!lMstes

=,:yand s naps .hut qlJicklywflen

Choke cable

al\dinspectlonoll h "cho k.plun~rs(see

23 Eogine-

oil and oil filter change

:O;~~=;oU=I':al:;~=':,~

~ ~:~~:~:~~~~~ra Is no oil In the ~

"'" Ll.l

:':7.:;~g'tlt:~" ~:7~~/ex:::s~

~::~::;:':::';:;':';~~~

oil 1 ConsisIenlroutine 011 end hiler changes ar.. Ih' , i"ll ie rTIO$l Important mainte nance pro<:ede intemal partS of

Ih' '''lI ine , tra nsm ission and dutch, bul ~ elso acts as e coolanl,.cleaner, a sealanl

:::!t~~~~~;;"~~n~a~~~

should be replacad otten with naw 011 01 tile racommeoded ~8de and type. Saving a ~tlie monayonth, diflerenceincost between I good 011 and a clleap oIt won 'l pay olf if Ih .. ""giM is damaged. The 011 filter s hOlJld be changed wllh every sacond oil change. : Ba/Ofe changing the oil, wann up the engineaolheoOlwi~drain easily.

7 II IhItchoke does nolaperetesmoothlylhl\l Is p
Specilicetions) in Ihecable bel",.lh, pI~ngers In tha ca rbo'ell",. mo",. II adjustment i, necessary, remove the fuel Ianl<, Ihen uae the adjuster in the middi601lhe cabIe,LJling lha method desalbed in SI"II 4 .bova lortha Ihroltle cables I.... iliust ..,lon). If this lalls to Imptova lheopa
~::~.~~~~~~:1~~~e ~:!:E '-;:;===-::;;-

3 Put Ihe mctorcyde on it. cent.e . tllnd (where fitted), Of support ~ upright using an auxiliary stand,anclposilion a cNtandrninlray

4 Nexl,uns crewlheoOldr'inplugl1'om tl>e 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

Maintenance & servicing

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
Inlo th.... ngin. and tighten th. bolt to the spedlie&ingltler
011

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
f~I"- ,ystem.Oon'rsmolteoraJ/owopef1

flllm",orbll", fightbufbsne,rlheworl< , '''", 'lnd don't worll in " g'n>~ w~re " nllfurlll9u-fYP8l1ppUllnc" i. p",Sflnt, I' youspl""nylueionyourskin,rinSllltoff inlnllldilltll/ywllh SOIIp andwllt" r. Wh lln youperlorm 'lnY kind 01 worll on tI,.luel

syst"m, III. " dviubl. to wur ,,'ery

""ve "

glns"s . nd fo Ii,. .~tingulsher 5ultllbia tor a ClassBI)'pefirrt{flllmnlabie IJqvIds/onhand.

~ tt heused~lforrecycllng.Don' tpou r

used oil into drainSo
Check

Maintenance & servicing re
'31>.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<:ured by twelve 10 mm domed nuts with pla in washers and two 8 mm bolts. which are locsted Inside tl\e cam chain tunnel. onest the Iront and one at ttle back. The nuts and bolts are numberad lor identification (see iHustration), Slacken them evenly and a l ;n~ at a lime in a reverse 01 their numerical sequence until they are all slack. Using a torque wrench,now tighten tl\e nuts evenly and a linle at a time in numerlcal sequence to the torque seltlngs specified at the beginning 01 the Chepter. noting that the8 mm bolts havealowersettir.gthanttlel0mmmrls. S IMta11the valve cover (see CNipts(2).

2fi Suspension - checks

I The suspension components must be maint ained in top opera ting condition to

25.4 Cylinder head tightening seq uence -750 models

_..

'·24 Maintenance & servicing -...... . . . . .fety.I.ooM,...."..Ofdam8oged ~sIonpe
foond,lheahockahouldbe,ep(aced(SM

~.

II Wrth ItMoaid 01 ... aMst""tto""l'J'Ol1thoI

Front s uspen$lon

bik.,c:omprtINtl\e • , ...... II should move up IIOd down freely

f,eepIooy'''' Ineitherc"-<:l
..,au$pellSlOn_"

2 Whi...tandlnQ.Iong.... lhemotorcycle.

wiIhouI~lIlIII'Iybinding.leIt.thewom

~ther.ontbr.kl.l'Idpushonlhtl

or fau/ty c:ornpOnent m.... ' beklen~roedlnd replAced. probIImcould be due 10 either the ahock abloft>er or the awingarm component •.

,0tI<.

handlw.r. to ~, the savera/ tim". See ~ thay move up-end·down smoothIywithoutlOnding.H~.faIl,the

lorbshouldbadiloassan'lbladll'ldlnspected (_Chapt.5) 3 Inlpactthearaaaoo"l thadu" seal lor signsoloilleakage.t'-C_ull)' ...... uplhl dust ..... using • ' ..t-bladed scrawmv. ond Inspect thel .....OUI'Id !helorksea/ (s" ilius ttI 1l0nl). lllMkagelsavideot.lheseal ..... tbe~(_(;hjtpI.5) 4 ChecklhetightoeuolailUlper'lSionnutfl _bo/tstobe ...... _haYe~_.

S lnspactthe .... ahocltIIOfnuid"akeoe rdtight_oIlhllrmounllngs.HlPakageis

28.7. Clleckinglorplay ..

n..

1Po.11iMthol~onl'-centr1l$tand ~fln..:l).or .... pponltUling ... auxliery

stand eo lhal lhe_wheeI is off thegr<:lUl'Kl Grab the twlr.gl.m and foek il from side 10 side-lhef• •houldbe nodl$ClII(nibia mo........" II u.. 'N' (. . . m", lratlon). II

tt......·••

~t1~mo ............. I

Of."'jghtclicking

can be '-'
btginningolIheChapl... and • ....::heck.or rno>te...etll.NaxI,grupll'lelopoltINt,U/ whIeIltldpull~ _ _ -u..shoUdbeno . . . . . . . . ~beIore .... IIhock.t>sorber

to COInP.KI ( _ illu st ration). Any

"-'be~_a.pw5). 8 To .... k. In _$SmeIl1 of

t.

..x:..... the _.therear""""

.~bMtIrIg •.

(tM~6)_ltIIIshockllb!orberl_

Chapt«S). GtnpltMl ',",,01 theawingalm witII",",lIandwod~your_IwId'1

the jun(:11on of lhelwingarm and tile frame TI'\I to move tile rN, 01 the swingarm f,om sid
the .wingoorm ~ not move frilly. the - . ......tbefl.rrl("'adlo<~Of ~(_CI\apI.5).

2S.7b ... lnthe ..... WIjMtIs;on

Maintenance & servicing

~~moontil1gbolls

28 Nuts and bohstightness check 1 Th"wlnga,mls&qulppedwllhagraasa nipple (Ieeillu.tra'ion). Uslog a &uitabla greaseguntiliftnippleandpumptt until a smal aJ'J'lOO..Or'l 01grease seeps pasI the _ Is on .... ch end 01 tl>
"25

FronrllXlelllldllXlec/Bll:pbolls Froll!fotkclampbolfs-

, Sinc;a vibration 01 tha machlrICI 'andSl0 lOQsen,a.t........s,~nu' •. boIIs.!lCrews. e'c Shouklbeperiodicallycheckedlorproper ,ighIMM. 2 Pay parlk:ularan..,tiQn10 the 1oI1owYog"

~e;:Ie~omyo/<eJ $wingMmpivotnut 8raireclllip<Jf'mo
~=hoseb8triOboIISandcaliperbl6ed 8lakediscbolf3M1d"""~t lMM

"""""'"

Ex/lMlstsjl!lemboltslnulS

Efl(JineoildrllinplugMldoilfi/terboit

===::boIf3

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

withthalOr'q.lespecilications.tthebegirw\ing

olthia,c
EngiMmountingbolfs

Every 12 000 miles (20 000 km) or 2 yearsZR550 B & ZR750 C Every 15000 miles (24 000 km) or 2 years - ZR750 D 29 Air fitter - replacemeot

32 Fromforks -oilcharrge

{ZR750D} 1 Fork 011 degrades amrll. per'<>d 01 time. and wli IQee its damping qualities. The '<:Wkslitted

to tMsemachines II.re equ ipped withdrll.in P'Igs,sothattheydonothavetoberarnoved lrom the yokes to effect an oil ehange. f'Iaee

30 Brakefluld- change 31 Steering head bearings -

lubrication 1 Ti>e brake fluid shovId be replaced at the prescribed inl ......1 or wl>
Chapter5,n(lling that aJlold tluld mus t be

~~ ::I~?'a!~~:~:£;::

1 DIsassemble the Slewing head for re:.":t'Is~ltIebeBring5.Ref... toChaPt.rs

groundu,ingajac:k .r>dll. blockofwOQd under the engine. To beQrl ItIesale side. ~ Is advisable to remove the fuel tank {s .... Chapter 3) to preve-nt tile po!Isibitityol dI!mage s.hould a tool stip.

2 S.""'"""butdoootr"""""",lha forl
3 Place a s"';tabiecontainerunder thed,ain screwoflhaforl
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<

~v~tt"!:~li~

ev::, (":, illu~~::':2;

t,,::

adjustment rnadfI by adding or subtractln;t oil Fully compress thelort< and measure thelor1< oil level 'rom the lOP of the tube (see iIIu.t
Maintenance & servicing

T Insta ll tl>e spnrlg . lollowed by the spoing """t arid th
.&. 1 •

1· 27

Warnillll: It will bto ...eN'.1)" to lh.¥rin1Iby~ _""tlle~usinglhelop

<:<>mp('e..

_1o~IIIe_o''''''

th,eadthe bolt Inlo t!>e top 01 ll>eforlc lulle

bonwlthlhefolfclube.Tltisls e polenti8lly

(see IMuSlfatioo). Scr9w II>e lop boll careMty intolhelO!l<. tube making aure ~ is not cross-

perlormedwlthCllre,u./ngannslsla,,11f

th,.... ded ,e ootighten it 'a tl>especifled

nflC
dB"9""us~IJo"

."dshouldbe

1000qoo setting ISH iIIuslrabon). Also tight..,

startingto_lthflpoa;bilityof~.

the ''''k clamp bolt s In th" top y""'e to th" spec;liedlorquese1ling.

9 Install tile handlebaf. (see Chapte<5) 8t>d 1he1uel 1anl« _ Chapt... 3).

Every 18000 miles (30000 km) or two years ZR550 B & ZR750 C

t Theprocedu,e forchaoging'hef rootfork od ls the.am"as lorlheother mode's(_ $&c\ion32)

Every two or four years - see schedule 35 Brake hoses - replacement

Thl3t8sJ<mustbecant.dou i """"Y two Y""'" ()tIZR55CBandZR750C~.tJrId9I'fIIY

wY"""'ooZR?SOOmodeis. 1 Rele, to Chapter 6 and dismanlle Ihe OOfIIIlIl
~

36 FuelhoH·re~acement

~

1IUs rask musrbecarri8dout8""'Yfour~

~~Oon!lhook:lb8r8PIacedregar
2 Aeler 10 Chapter 6 and disconnect the bra ke hoses Ifom the mas ter cylinders end cal ipers. Always replace the bMjo un"", ......ing washerswitllnew""""

ThislssllmuslbeC8lriedouleveryfour)'Ht"S. Wllmlng: Pllfrol (gaso/inll) I. I 1Ix1r11me/y flammablll, so lakl • lIx1rll prftCllu/;ons whlln you work on any PIIrt of the fUll' SYSI. m.Don·lsmolrllot"_ .. ~f'_ ot"barelighlb<Jlbs~rtll...(ri..,.,.., and

.&.

' · 28

Maintenance & servicing

don'fwm in II g""'ge wll ..", . ".'ur.' gas-ty""appllanclt/s pnls."I./fyousplll " ,,), f"ltl 011 your s ~I", ri"S. if off

;m"",dia 'a /ywitllsoap lI"dw.'"" _ II"

• .,nablefor.Cllln B /)'p9 f1rw(f/8rnmable on Mnd. ~=lonshooldbe,,,,"acIId'e.gardles301 I/qukls)

you""rform,,"ylrlndofw onon,h. ' ,.., system, II is " dvi." bllt to w..r n f. ,y

2 Remov.. 1he lue' tank (s,", Chapta. 3) Disconnect the luef hoses lrom thelue! tap

11'. U U

and from the cartluretlors. oolinglhtl

a"d '".v . ..

lire IInlng""".'

rou~"9

01 Net> hose and wh ..... it connect. (.""

Chap! ... 3 ~ required). n is ac:Msabie 10 make • sketch of the varlovs hoses belore removing them 1o IKl....... 'hey ..... comoct!y in.talled. 3 Secure &ach new hose to ~s unions using new clamps. Run t he eng;r>e.r>d cl>&ck lor 1eaI<. belore taking the bil<e oul on the road

Non-scheduled maintenance bearlngsbypushlngandpull inglnewheel

37Head1lght almcheck and adjustment

~ ~~~s:ht:t~h~o~:a~SOsn'.:I~Iy~hl~ :n~a~nl~ ~

NOIe: AnlmptOpl1rly.djlJsledhNdlighr"",y cauS
deteclable..,thehub,or il theWheeidoosnQI fQtDle smootNy (and thia Is IlQt due to brake 0, trans mlssk>n drag). the wheel bearings must I>tI removlldand"'5p8Ctad lor wear or damagelseeCha!lt&r6)

~;<>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 lhesparlgcn the OUICome ot the = e s t . a squin-typ" ojl can may aloo !)e

40 Englne -oiJpressurecl\eck

~

~

1 Tocl>eck the 011 pre$Sure. a .... tablegauge and adapte, plec. (whlcn sc,.ws Into Ine cranl
and

:~s~~:~~e.:t~~~:tant~as:at~:a~~ (~: adapt8f. 4 S tart theenijineand incr... setheenijine speec! to 4000 rpm whilst watcNrog the gauge reading. The oil prassure should besOmiIa,to thet ijI""" In the Specilicationsat the start o! thia Chapler. 5 If the pre&SUnl is significantly 1ow... 1han the standard.eithe,lhepreswreragulatori.

::~~~':';~il l:eIS°::.:cu::. i~ ~:::'i;:~':

engine damage. BeoIn diagnosis by checlenlheojl pump (s" Chapter 2). II those item. check cut okay. cnanc .... are the bearing 011

=~~:.:~:.::~i ve and the ""gine

1 Place the moto,cycle on Its centre stand (whe<e fitted) or support il upright using an auxitlary.tand. Check lor any play In the

torque setting lsee Section 25) 4 Aete< to Faull Finding Equipmenr In the Aelerence section lor detail. ot Ihe cornpre$SIQnlasl

6 Iflhe pressure is too high. etlher an 011 passage Is clogged. the ' egulatorlS stud cIo$ed or the wrong gradeol oil is being used. 1 Stop the engine and unsc,aw the gauije and adapt ... Irom lhe crankcase 8 Inslan theoit ijalle
37.2 HelidWl/ht beam horizontal adjuster screw (arrowed)

37.3 HeadllghlbeamvettlcaladjuS!e< SCrew (arrowed)

40.3 RertMlYe the oil uallery piug(errowed) and instalt ltlepnossuregaull"

38 WheeJbearings- check

~ ~:;:~ :~;·(s'::·~~~~ l~i~;:~~~t ~~: ~

cylinderllead nuts are Ilghten/ld to lhe correcl

Chapter 2 Engine, clutch and transmission Contents AIItrnator-remova I8f1d ios ta ~a1i0ll

......... SOOCha pte<S camchainand~ades-"''''''''aI,inspection andins tallation. .10 Cam ehaln I_loner - removal, lnsp8Ction and insta~ation . 9 GamshaftsandlolloW
g~=~r=~r= 'nSlaDatio
seeChaPter;~

CylInder head and va/Ves disass«nbly.iospectionatld,eassemb/y Engne - .8lTlClval and Ins ta~ ation Engir.edisassemblyand'eeS$(!ll1bly -~al ln k)rmation

..

,.

Major ongioorepair - g oneralnole . Neutral . wrtch - check. 'emoval ar>d installation....

g: ~~~~~~~~inslal l ation Ollevelcheck.

_

• Chapter 8

... . . ........... 7

.S
O ~ press"'
~:;:="n~~fe .,~ : ~emo·.aI. r-.spectionand Operations posalblnstaDation..

22 2 . 3 . 16

. ..

. .... . ... 17 R
Ge=:::I;:,~( xtemalcompooents) - ,emoval. in~~o

St=~~t:? idl~.~.~.~.~~,.~bIy- fem<>ll~.ios~~ ,

~'a1lnformalion

StatermotOf -rnstajlatloo

1

ld1espetldcl>eckand , djustment ... _.. '._. _, _.

.sea Chapler1

::~!££a1;::7t~,C~'~~.b.~:

~Chapt...~

..

Main and connectir>g rod bearings- general note .

. .... 26

_Chapter 8

~;==::~::~~~.!~':~.'~~.bIY.:::~ ~:::~=~~k=~:~I~,,=t .. Valveslva/ll.seats/V~ guid
.._Chapter ~ 13

Degrees of difficulty

2

Specifications ZR550 model. Four-stroke OOHC In·~"" fOlK

"" ~

58.0mrn 52.4 mm

9.51'" Wetmulti' plate Si.-speedcons.tantlt1ainar>dsptOCl<ets

_.,

Cylinder block

,,"

We ar im~fmax) .... Cyljrdeo'comprnsion

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) ................ . Carn<:h&ln21 pin length (..... teoctt

~!~~~~. and springs Inlakevaw. Stem diameter •.. . .. Guide~diameter . . ... . Slem·t<>-gUidecle.........,. .. .

~=~~(~eetext) ..

~::,;~ 5temrunoul EJ
Stemdiameter ..... . Guidebofediameter .. . 5tem-to-guideclDarance . .

~=~~~(_ te.t) Seat width Sealr:t.ameter . ... . Slem...-.out{maxf ....... .. ........... . Vaw.sprtngslreelengtllCootakeandewUSlf Original parts I~spr;ng.

Outer.pring ... . Repiacementparts Innerspring

Out... spring

~:~~:~~g~

:::

21.900to2 t .922nvn 22.000ro22.021nvn 0.078toO. 121mm O.10mm 127.0 to 127.4 mm

~:'::::'"!,,,"1 5.47StoS.490mm 5.500 to 5.51 2 mm

g:~~:O~09CXJ~:m 0.85 to 1.15 mm 0.510 1.0 mm 26.910 27.1mm O.05mm(maxl

36.1mm(mOnj 36.1mm(min) 21.87mm(mOnj 22.08 mm (ma>rj 0.21mm(max)

Seriie.limlt 5.46 mm (min) 5.58 mm (max) 0.12 mm (max] O.24mm(malIt 0.6 mm (min)

5.455 to 5.470 mm 5.500lo5.512mm 0.030 to 0.057 mm 0.07 toO.13mm 0.85 to 1.15 mm 0.5 to l .0mm 22.9to23.1nvn O.05mm

5.44nvn(min) 5.58nvn(maxj O.1 4 nvn(max) 0.28 mm (mal<) 0.7nvn(m"')

36.7nvn 38.7nvn

35.1mm(min) 31.1mm(fOO)

37-25nvn 4t.85nvn

35.8 mm (min) 40.2 mm (min)

Pistons pjSton diameter (mea ...ed 5.0 nvn up ffom sk01. at 90" to plstoo pin ""is) Standard. .... ..... 57.965 to 57.980 nvn SfIfVIcellmlt(min) ..... 57.B2mm Piston·to-boreclearance O.02OtoO.047nvn

~~=:e"

:~:~~~

Piston rings Endgap r. ns~ed)

Standard

Top ring and 2nd ring 0iI1ing . .......... . ........•....•.... Piston ring tl"lid
g~:~g:~;:: 1.175101.190nvn

-....

O.60mmlmaxl 1. 0mmlmaxl 1.1mm(mln)

POston rlnggr<>oVftw\dth

Topring .. 2nd~ ng . ....... . ...•.

1.31mmlmax) 1.33 mm (max)

Ring-to--grooveclearance

''''''''

0.020 to 0.055 nvn

1~~t;: ..

~.~!? 075mm

2ndovemze

+ 1.0mm

Clutch Friction plate

~~ .. Standard .. ServIce limil (min)

w.,.,._ Piainplalll

Ouan~ty ...... . Warpage(m&>
2.9 to3.1nvn 2.8nvn 0.3mm

,

0.3mm

0. 16 nvn (m&><) O. 18mm(maxl

Engine, c lutch and transmission 2- 3

ZR550 models (continued) Clutch (continued) $prinyfmelMglh Standard .. . . . . . . SeMce Imit (min)

32 .6mm 31 .7mm

2.934101 (27123T . 6SlZ6T) 2375101(3611611 2.562101(4111611 2.57110 1 (36I14"D 1.777 101 (:l211BT) 1.380 tol(2912 1"D 1.125101 (27124"D 0.961 101 (25126T) 0.851 tol (23127T)

Selector drum and forks s...ecto
().()51o().25mm 4,9t05.0mm 5,()StoS.15mm

~::,:~~~~mm 8.!l5 to 8.20 mm

Crankshaft and be8l'"ings

SeMcelimil ().45mmlma><) 4.8 mm lmin)

5.25mmlmax) 7.9mmlmin) 7.8mmlmin) 8.3 mm (mrur) SeMcelimi!

~.ci~~~.~~:m ~:g~ :~.~r;:~

~1s96=(min)

O.13 toO,33""'" 32.9841033.000mm 0.G3510().OS9mm

0.5mmlmax)

Connecting rods Big-en<.!$idedearance Crankpindlameler Big-endo'cfea(""""

J2.97mm(min)

0.10 mm (mW<)

lubrication system see C/1.a!Iter 1

Oilpr$S$I.lnI . .

Torque settings Eng ..... ....,...,l lng bo~ s and rIIlts .... EnginemOO'"l11ng bmcketbolts Pulse generator as$\KI1b1y COV(ll" bo~s

Oilcoolerhoseunionll\l1$ .. . OiIcooI8thoseunlon~lS.

VaI"",cO'llerboits . Cam cha in tensiorler

moun~ng bolts Camchain t ..,",,,,,,,,"capbo~ ........ . . Cam chain tensioJO" I>Iade ptvol brackll1bolts Camshaltcapbolts . . . Camshaft sprocket bo~. C)'Iinderhead8mmnuts .. Cylinderhead6mmbolts .. . .

~nu~.k.~~~~~ :: . Ch/ld>press ..... pla.lebollS . . . .. .. . . .. . . . . . GealcltDr>geshaftco;ntraiisingspringlocalingpin Gealchar>ge mechanism boKs $t<01ercIUlch Alk!<1 bo1ts Secondaryst.a.f1nut ()jIpres!IOI".. regulalor OilsumpbojlS .. .. . . Crankcase6 mm bolts Cranl
00_

~'m 23 Nm 10 Nm 22Nm 8.8Nm 12Nm 12Nm

,'-

12 Nm 12 Nm 15 Nm

25Nm 12 Nm 9.8Nm 130Nm 8.8Nm 20 Nm 10 Nm M 'm

"'m 15 Nm

10Nm 12Nm

29Nm 24Nm

2

2-4 Engine, clutch and transmission ZR750 models General Four-stroke OOHC in- line tour

"'~ Wetmu" i·plate Five-speed constanl mesh Chain and sprockets

Camshafts IntakecamShafllobelleight .

=t~=::fllobeheight Journal holder d iameter Joo..matoilclearance Runout(m&X) . . . . ........... . Camchain 21 pin letlgth (see text)

Standard 36.245 to 36.353 rrm 36.24510 36.353rrm 21.94oI022,04omm 22.0601022.081 mm

Servlce lmit 36.15 rrm (min) 36.1 5 mm (min) 21.91mm(min) 22.14 mm (max) 0.23 mm (m&X)

Cylinder head Warpage (max) .

Valves, guides and springs VaIv
see Chapter 1

7.000t07.015mm 0.030100.065mm

fffladthlckness .•

6.94 mm (min) 7.08 mm (max) 0.14 mm (max) 0.30 mm (max) 0.5 mm (min)

Seat wid th .. Slemrunout(max) Exhaust valve Stem diarneter .... . . Guide bore diameter Stem·to-guideclaaran~

Stemdenecbon(seetext) . Head\tlickness

0.030 10 0.065 mm 0.0610 0.14 mm

6.94mm(mln) 7.08mm (max) 0.14mm(max) 028 mm (max) 0.7mm(min)

Seatwklth .. Seatdiameter Stemrunout(max) . Valve springs 1fee klngth ~ntake and eMaust) Innerspring .. OuterSpring

35.9 mm (min) 40.3 mm (min)

Cylinder block

.,"Standard.

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 5electorforkgrOOV<'lwldtll 5eleclorforkguidepindlameler

7.9 mm (min) 7.8 mm (min) 8.3mm(max)

Inpulahafl lork. OIJlputshafllor!ls ..

SelectordtumgroovewKllh

Crankshaft and bearings Journal diameter. .

. . . . . . . . . . . . . . . . . .. . . • . .

35.gS41036.000mm 0.020toO.044mm O.05mm 0.05100.15mm Ot05mm

Setvlcelimlt 35.96 mm (min) 0.08 mm (ma>;) 0.35mm 25mm

Connecting rods Big · andsldeclearance . Crankpindiameter Big·(!(Ido~clearaJ1oC(l

34.984 10 35.000 mrn 0.036100.066mm

lubrication system OiIpnlSSUre .. . .. . .. . ..... . .. .• .. • ,

see Chapler1

0.48 mm (max) 34.97 mm (min) 0.10 mm (max)

2

2- 6 Engine, clutch and transmission ZR750 model. (continued) Torque settings

. ....

EngNmounting bOMand...". .. EngNI'I"IOI.O"Itingbfac:QtbOM .•...•... PulsegeneraIOf~~bo/I!; .. 01 cooler hoM union ..... ... . OIcooIerhoMunIonboH •. . V_~bOM ............. .

"

"

'2 Nm 'O Nm ,ONm

Cllmchainlenslonlrplungerboll ... .

Cam chain lenlionef moumr.g bolls cam chain tenlionef cap boll ..

"

,30Nm

Clutdl~pIIo.l.CoU •...................... ~_ftCltltralilingapringlocatingpin ..

roNM

"

~=~bOM

~~

~Wftnut ..... OIpr.-nNgLUlcr ..

..

""

.

...-

SeIectofdrumguideDOk

--

" "

NM NM

,

1 General lnlormatlon

~".nUmbet "ff""to~tobi

~18tISIo
Theenginellrlnamll8lcn unit if, an airIt...., per cyIinderIW.cpw.I.cIbydcutlle""eofflhe cocIed in·1ine lCUI. The v .... "

~. The~assembIy

Is construct.cllrorn .'uminium alloy. The ~lao;lMl;l.,;lhcltmn~.

The o;tlr\kc... inc;orpor.l. . . wl1 sump. ~1Idit.ll:>rbIlonIlY'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 *
=:..~~~.:

NM

~:::

....... oil liRM

In andby·pau"a/Ye.....,.bIy,.~,,~and

an oil pr ........wildl. Power l,cm lhlC,ank.haft l,tran,m ltted vi. a Hy·Vo primary chain 10 the secondary shallwhichrunsDlhlnd lheC'Irlkshalt.The secondary lI\< canlea l he"atterclUlch .ssernblyandprcvkle.gea'd...... lolhe dutdl.whichlaolllMow8l.multi-pial'lypI. FmmllModutch.pcw.- '-lrwIIrnittIddirectly tollMoir4lUt"'-""'IIMo ............... which .. a(750nwxIebI Wt-'9Md _ IS$O models) _ Of. five·&peed unil

~tro\:ICItpfl/ons_pislonrinrp 19n/IJon_andptba~/orcoil

--, """"

probabIylhe~_irnportar"Itl_.flII

==:-~{utam.I~

Imml",,"'ame. H_.anumberolareas requir• .,tantion at 1IMo_ ...... ,emOVaI 01 1IMoengi'>a Is ,acommandad.

engi'>alhalhesragularandlreq.,enloiland _~IInCIClhwNqUAdfTllinteNra.

S-cAnchandldle(1l!W

wIII"-tlikely~manymilesol_

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

....-.Ic
s_ _

=:::-eA:-:: .......

..,.....,~'Myeartyinllsw..

.......,

3 OperatIoll8requlringenglne

....,.uary

arnoI<• •nd ",xcltSsive oil conaump!ion" tIoth indications that pislon flr>gl.rK1IOf\l"v, guklltS ar, In need 01 . n" licn. aROOugh make sure that lhe laull II nol dill 10 011 IMkage 4 Ift""angif"411 making ctMousknockingOf ,umblingnol...,t""conn""tlr>g,odandlor 3 Exhau.,

,amov.

II .. 10 lhe ""IIi"'" tr.,.tmllIion ....... blylrcmt""'rameand ........ the crricaH ....... 10 gain access Iclhelolowingcomponenll.

,--..-

--

mainbearinglareprclMblyat leUI 5 LOll 01 pow ... ,oughruMir>g.'xcesaiv,

varvatrainnolaalrldhlgh luelconsumption ..,. . may allO point to Iha need !of an ~.aapacilljtyWIhay ...... the...,.,. ....... II a cornpIete tune-up does not

presan'"

Sa/ecforcN'nandlbrb

..-:tyllMolitualior\maiOrmec:Nnicalworl< lalhefldt.wtlon·

"""""",

e flll""lli ...

=fO(ItJig-andsandbearings

The ccmpon",' s and .... 6mbli.' li'led C8IOW can bI ,,,"ov..:l wilhcol havir>g 10 ,emove 1M englnellr. n .mIIlHln .lIembly

2 Highmilelgellnot.--sarllyanirdicalion that an"""""'''.-MeI. wtileicw mileage. cntheClhwIWld."'-not prec;lJdIollMonaad IOfanov.haul. F,aquancyol_ingla

.. Majorenglnerepaw -

general note

l l1i1notalwayweuylodelenninewhenorW ananglnaahOukllMcompialelyoworhaulotd.

""am.uto-'allyin~

rHfO!lng ''''' inl ..... , perts to ''''' opaelIicllicnlolanawangin •. ThepiSlon ringI.ndmalnlrldconnacting,odbearir>gs ... u. ually'llPl.cad and I"" cyfindMw.lI • honad or. If nece ... ry, " -Corad during. majorovert\aul.~a.IIy ' ''''va '''' seats .... ...-ground • .n.:.lhey ... l/SUlllyinlesslhltn perlectccnditlon.,Ihi. pcint.Theend,""", 1houkI1M.'ikanawengine thatwill givlas many~" .. mllelaslheoriglnal.

Engine, clutch and transmission 2-7

,~.,~, I

\. I. ""'" ~. >dl~fI.,F~ .. /: --~,. ., , -'-II

.

,

"

5 Engineremoval and installation

_

' .

.

,

,

5.5o;...,on<MK:t thenegati ..... lead,..;AI"theconneclor 7 Belorestartingtheertgineoverhaul,read IhrolIghlhereialedproc;edurM tofamlliarlsol yourse/Iwith thescopeaodreQl.kemenh:otthe Iob_ OverhItu!lng an engine;' not all Ihat difficult, but ~ is lime consuming. PlIwlon tile bil<8bW1gliedupfot a mnnumottwoweek5. Checldle the Inspecllon 01 parts and off ... Itdviceon.lICOndilioningand te\llacemeot. As a general .ule, time Is lhe primery cost ofMover\IauIsott does not pey lo inslalwomor-S
..~

5.10 "'ake8Ii~=;;;~:~:no=:,,'.,~bol1tam>~

any major dlsmantliog ... orl<.. This will ma~e WOfI<much_ier andruleoutthepossibility 01 cAked on lumps 01 dlr1lalli r>g 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
Feed ttlelMdlhroughlolhllengineand cm ~

on lhe crankcllse,noIing Hs routing 6 Rernovetllefuel tank (see Chajlter3). 7RlIITIOV
t,ont sptOCket (see Ch8pter 5) 12 Rernove the c:Mch cable (see Section 19). 13 Ofl 550 models, unSCrew IhII Iwo bolts securir>g lhe st.n... motOf top co .... and lift

offlheC
~1::,~=s:!"':~\~r1er motOf lenninal IIl'
'" 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 sta
2- 8 Engine, clutch and transmission

15 A ~ tne ig"Wo"p<>~g_ato< coil

assembtyeover (u. Ulu .trlUonl ,th
ignitiorlcorrtf
the crlnko;ue 10 thlt It doaI not Impede

erogm ,....-.... On 550

moo:\M,dlscorv>ect

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 'Niring<:OMeclOl'oMtlMoawitcn. t7 RamD .. Ihe igNtlon HT coils (re"" toO

•.

Chtpt.4~ 18

~'Ihe.~halJStay$Iamlraler l D

"-

t:>rackat 100 Ihe lramedownlubeand ramov. Ihe bracke\. IlOling how it !it. (s. . llluatralloml. 22 Mak. sura Ih" the angina Is property so..ppo
I II Aemov. thaoilCO
.......,.;ngtheangO'le(H.CIIIpt.-~

ro At Itlls poinl,poallklnanh)'draulic: Of ~ld.tJndarthe ....... Wlthablocl< Of wood baI_lheJack haad and sump Make ...... 1hal the)8ckIsOlll'ltraily positiol'lad 50 Ihal the angina will noOI tOppia in any directloOn wh.n the last mounting bolt i. ' &rI'IIlY«\.Tak.lhewalght oftheengl""on the

"".

21 AamoYl theang,na lront mounting nuts

arHl bolt., tharl r...... v. the nuts arHl t>oIt. securing the righi-hind Irontangil'la mounting

5.2l aEngllM lI'ontm
Engine, clutch and transmission 2- 9

.& ~:~£:i~ ~~fd;£!~~; themkofflfa.

2 When cleon and dry, amonge the 1IO~ "" the wDrkbench . leaving su ilableclear area lor workinQ. Gather a selectioo of sma ll containers end plastK: b.lgs so that pwtscan begrouped tooet hINinaneasllylde<1lillable tn8mw. Some paper and a pen s hould tle "" handIDpem"lit "",,,,, totlem_andlatlel$ attached-.I"o8<;.ssary.AsvpplyofQeen ragisalso~.

3 6eforecommencinQwork.readthrough tlle 8WfOI)riat"sectloo so lhal some KIea of the necll5saryprocadu re can be gained. When removing various eng ine compone nts I, ShO<J1d be noted rhar grear force is seldDlTl requirec:i. unless specified. In many cases , a CDlTlp<>r>tInt"s .W<;lanca to be remo.ed is ndicali\leofanlro::on"ectapproach""rernoYai =.hod. lfinanydOUb t. ra.checkwithlhe 4 All engi"" ..... ppon stand made lrom shorl IenQtha ol 2x4tJoiledtogether into a "",tangle will help support Ihe en-glne (ue Illu stration). The perimeter of the mount should btl just big enough 10 accommodale

5.22b FIe .... ..,o..mtingbracketbolts (arrowed) - 550 mode ls support h n wejl. Aemo.e the nuts on th" leU-hand end of Ihe lower and upper rear enQlne mountlr>g 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<eS
=~:=":7==boIti$ cjln$ta/f therearqngl""moutItingboits fromtherlght-/wIdslde.11Ie/otlgelboit Isfoftheupperr8NnIOIJfIIirl$i',endlhe $hOItWfoflr../Qwe<"retNmounting. d)OOll(lrfu/l)'tlg/lren ....yofll!eboltsuntil Illeyha",lIIIoeenlnsffllled. Mike sure II!e

brlJd:iets.ncorrectlyposilioned. e) Jlgh!enrlleqngl""moontingboltnuts It>emountingobrlJd:iet boitnursllldany otherboltsMdnuts lo!hetorqueselfinos 5pacified . , !he I»ginningof tile Chaptar.

6 Engine disassembly and reassembly -

general informalion DISlJuembly

Removethe~mechanism

eJ(temaicomponents Remove rhestarfDrcJrJtcI!endidfegeN Remove tlleaJtenuJror{3eeClMpIMB) Removetl!estaJtermotor(seeC/wlterB)

1 Selore disas""",biing the ellQ irM . tile ..lernal ..... rf""115 01 Ih. unlt.oo...!d btl IhorDoghl)lcleanedenddegr .ased.Th~will

PI'-' contamnatlon 01 the engine Internals . end will al. o make woricinQ a lot ea"8f snd clean",. A high Ilnh-poifll sotvent. such as paraffln (l<erosene) can be used. or betler SIIlI, • prOj)rietary e ngine degreaser. Use old paintbrushll5 snd IoDthbfushes 10 wcrk the 5DIvenIinlOtM"""""'"",,,,,,,,,, oftheengirM cuing •. Take care roe.ch.oo:Msotverot ""weter l romtM~ec l r i calcomponents and inlake and exhaust ports .

L:--:---:-----,----:-:--:----'

2- 10 Engine, clutch and transmission

Remove the oiIwmp Remow the oil pump ~terJMCIlinIIcasehaMts

fIemoIoe the CflIf1ItM>lIft fJ/'Jd COB'ItICfioIg

.-

Remove rhe rransmis.sJon shsfls/~ ~ve the sel6cron1wm and Iorlts

us&d. If required . uMacrew the nut seeurlng each hose union to the bottom 01 the cooler and detach the !loses I s" IlIuslra tlon). Discard the a-rings as new ones must be

......

3 Unscrew lhe three bolts sec"';ng the cooler

10 the ,,"arne, IhfIn carelulty rerJlO'Ie the cooler

Reassembly

I'" illustration).

7 Reassembly Is accomplished by reve<sing Ihe general disassembly sequence.

Insta llation " lnstaOa tionisther",-o lr~ va/.

Always use new O-rings when imtaillng til'

7 Oil cooler and hoses removal and installation

~ ~~~~~et~e=s~~~~~t~: ~

NO": The 011 cooler and ItI hoses can be rwrICMIdwittJ the engn. ... lhetrame.

Removal 1 Drain tha 811!1ine oil (see Chapter lj. 2 Unacrew lile bolls securing each oil cooter hocseunion to the oil sump lsee mustratlon) . Discard Ihe a-rings 81 new ones must be

bflglnnlng 01 ti'I9 Chapter.

8 Vah-e covet" removal and installation

~

Removal 1 Remove the Hal and lhe side panels lsee Chapler n and disconnect the battery negative (-)Iaad . 2 Remove the luellanir. (see Chapler 31. 3 On US models. releaselhe air Sl.IC1ion va/ve hose clamps and detach the hote$ lrom their unions. Remove the valve wllh Ihe hoses altached. noting lhe rOOllng 01 eech hose. 4 Disconnecl the spark plug lta
~ ~:!e~:';:"~hNd.lI~ ~

Note: The valve covtr can be removed with theeng/n6inrhflframe./frheenglnellasboo/1 removed, ignore the $reps which do I'IOl apply.

is stUCk. do nol ''Y to ltv.. ~ oil w~h a screwdrive<; tap it gently 8rO\lnd the lides with II rubber hammer or block o f wood 10 dislodge It. Ramove th a gasket and the camshattetIdplugs

Engine, clutch and transmission 2- 11

Inst alla tion 8 Exam ine Ihe va lve cove< gaskel and camshal1 ervd plugs fo< s igns Of damage 01 Oetenoraliooaod,eplacethem~n&C_ry

On 750 models , Kawasaki rltCommend thaI lhey are repacedpl~ s m,lhen iM t aill he plugs

wilh the flattened itIner sectiQn facing up (_ IIlustrationsl. 10 u.y lhe gasket O
making sure a il lhe boll holes align (see iII"s trlltion). On 750 mod~ s the lab on the gasl<etmusl beOOlhelelt·handfronl po<100n of thecytinder head. 11 Posillon the valve cover on lhecylinder head w~h Ihe arrow on lIs raisad centre sltClion facing forward. making s ure Ihe gas ket Slays in place and the cove' locates COn"ectly (see illusl,ati...,) . lnslalilheoove, boUS !II"
!.:I~,:eo;=~~ components in Ihe

9 Cam chain tensionel'" remova(,inspectionand installation Note , The cam Cheln tens'onM c.n be remoffldwitllllle engjneintlleframll.lflhe en9·nehasbeenremovtld.;gnorell!eslaps Ihatdon·tBPP'Y.

ZR550 81 and 82 to fram e no. 064686 C.ullon: One. you s lenlo remove Ihe fens/o"e, b<>lts. you must remOve Ille lens ;o"e, all Ihe W'y end reS.1 It be fora IIgoh!enln" '''ebolls. 11»1ans.\:lnerufends _ _ locbinp/ace,soilyou/oosenth<J bonspartwsy . nd lh"""'tiglllenlhem,llI. I...wor-orcam chairl_badamaged. Do noltOla!llh<Jcran/r.sII.9ft """'/he~ 1t.9s_~.

Removal , Remove the cari:lureltors (see CMp!l)r3) 2 Slacken Ihe lens ione< cap bolt. Ihen unscrewlhe Iwo lension1"mounling bolts

Inspection 4 Examine the tens lone< components lor slgns of wear or damage. 5 Removelhe l~ capbolt. [)jscardthe

O-ring as ar">8WOIle 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 l0llegeris seized In the body or theSj)ring mechanism broken. the tansloner must be replaced. Tile Inlernal components of Ihe t_ _ ,,",oolavailabieindMduaily

7

F~anewO· ringoololhel_"""" body.

2- 12 Engine, clutch and transmission

8 If not already done. remove tile tensioner cap oolt . Oiscard the a-ring as a new one must be used. Using a Uat-bladed screwdriver. tum the slotted end o f the tensoo8O' clockwise to release the tensioo and allow the plunger to retract fully into the tens.ionerbody.Koopthescrewdriv8O'located in the slotted end of the tensione< to p<event the plung8O' springing back out 9 With the screwdriver stHi located. fit the tenslonerlnto the cylinder block and Install the tensioner mounting oolts. Tighten the oolts to the torque seUing spocified at the b&ginning of the Chapt8O'. 10 Remove the screwdriver from the end of the tensioner. As the slotted end tums itself back. the tensione
advisable to remove the vatve cover (500 Section 8) and check that the cam chain is tensioned. If th is fs not the case. remove the pulse generatOl' assembty cover and tum the crankshaft cklckwise using a 17 mm socket on the timing rotor hex (see Illustration s 11.2eandb). Cal.llion: DO NOT I.ISlI Ihe liming rolor boll to Il.Imthecranlcshaft-ltmaysnapO<'strlp Ol.lt. A/Sobe sl.lreto Il.Im the angine in its nannal dire<;Iion of rota lion. Set the rotor so that the T mark aligns with the static tim ing mark on the crankcase. It this does not cure the problem. remove the tensionerand check Ihat it has beerl correctly Installed. Also che.:k that the valve timing marks are all correctly aligned (refer to section 11) 11 FitanewO·ringontothetensionercap bolt and t;ghten it to the specijiedtorqlHl 12 Apply a smear of sealant to the crankcase joints on the pulse generator assembly cov8O' mati ng sorface (see iIIustration9.24a) . Install the pulse generator assembly cover using a new gasket and tighten its bolts to the specitied torquesetling (see illustration 9.24b).lf removed. instalithavalvecover<soo Sectioll8)

ZR550 82 from frame no. 064687, 83, 84, 85 and 86 Caution: Ones yol.l slart to remove Ihe tensions' bolts, you must remove the tsnslonsf all the way and reSS I it before tightaningthebolts.ThetensJonerextends

moveslreely in and out of the tensionef body (s_ illustrations 9.2Oa and b). 18 II the tensloner or any 01 ~s componen ts afe worn or damaged. or if the plunger;5 seized In the body. the tensloner assembly

::s~v~;:.aced. Individual components are

itseJfand~inplace.soif)'OClJoosenthe

bolts partway and then retighten them, the lensioner or cam chain will be damaged. Removal 13 Unscrew the tensione< spring cap bolt and withd raw thaspring Irom thetensioner body (see illustration) 14 Unscrew the two tensloner mounllng bolts end withdraw the tensioner 'rom the back o! the cylinder block (see Illustration 9.13). II ~ is difficu~ to remove. there is II little tab on the right-hand side 01 the tensioner which can be used as a leverage point \see illustration) 15 Remove the gasket from the base of the

~~:~~~r a~ra~:' a:::e~~~:e~~~k

and

Inspection 16 Examine the tensloner components for signs of wear or damage. 17 Re~se the ratchet mechan ism Irom the tenslonerptunger and check that the ptunger

Installation 19 Unscrew the bolts securing the pulse ge
~~::n;-:,s;I::Is,::O:o..,tt~'::o~~e engine in Its 20 Ae~setheratchetmechanism andpress the tensioner plunger all the way into the tensione< body (soo Illustrations) ~-....,

Engine, clutch and transmission 2. 13

21Plac· · .-..wYBske IOlllhe lens ione, bod\I.It\enIn'IaIIH ln lheenglne.rMi
:~~.

(_Section8)a""checl
is lensloned. li lt is slack. IhtI tensloner piston

ZR'"

Caution, Once you s ta rt 10 ",move Ih. t."~lo".r tH>1Is, 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.. terISiotJe<"orcamchein_blJdlNnaged.Do

"" ............

notrot.91eu..~sIIlIfIoncetlle_

25 Remove the start. motor (see Chap!8f 8).

26 Unscrew the t9llsloner cap boll from Ihe sideolthe tenslonerbodyandwithdfllw the Sloppet spring aod stopper (see Hlustration) 2.7 Uoscrewlhetwotensionerfl'lOUllingbolts andwithd,awtheteo&ioo.'romlhebaclcol Ihe cyinderblocio (seeHlustnItIon9.33j 2.8 Remove the 9/'Skel from the base oIll1e tens ione< Of /rom the cyliooe< block and discard~ as a IMW DOlt """"I be used.

2- 14 Engine, clutch and transmisSion Inspection 29 Keep;ng your thumb on Ihe plunge.-to prevent it trom springingoul. unscrew the plunger boll Irom the side 01 thelensioner body (see Nlustratlon). Remove the boll and relaasetheplungllf.thenremove~aIongwnt>

the plunger ,pring. Cheek that IIIe plung&r rnoveslreely Insnd out of tile tansioo"w body. lilt does nOI. clean sll components w ith solve-nt and apply molybdenum disulphlde grease to allmovingparla 30 E ~ami ne Ihs tensloner components lor &9nSor wear ord~ (s"lliustrstion).

31 li the tensioner or any 01 ~scomponent s are worn or dsmsged, ()(II tha plunger Is selzed In lhe body. they musl be replaced. ~eornponen1Saresvsilabie.

Installation 32 Instsll Ihe plungertprk>g and plunger into \llelensioner,sligrWlg tile slot ... lheplunger wilhlheplungllfbolthole (seeillustration) . Press the plung¥k"lto the tansioo"w and k"lstall

\he plunger bolt and ~s washer, making Sin lhebollendlocatesinlheslotintheplunger (u. lIU$tration 0.29). 1lgh1en 1hebollI01he lorquelelllr>gspecitiedal lhebeginningol \he Chapter. 33 Place a new oaslr.et on the lension« body, lhen mlaillhe tensioner. making sun the IorIgerboltitinslall&d uppennost and with It$ 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 1herotorSOthalIheTmar1
assembled. With the stopper COffeelly In$lslled,lnsl all Ihe spring and cap bolt wilh itl wasller (see Illustration 0.26). Tighten the eapbolt to th es.pec~ied l orquesell ing 35 It IS advisa ble to remove the valveeover (seeSecUon 8) and check that the eam ehaln it tensioned and that the valVl! timing marks areallcorrectlya!ignedlseeSeetiont l ). 36 AppIyssmearolsealant tolheerankcsse joints on the puissgenerator assemb/yeov. rnatingWtl_ l see iNustraIion 9.24aJ. lnsls!1 lhep!.llssglM'llll'3lorassemblyeoverusinga new gaslr.et and tighten ila bolta to the Speeiliedtorque (s ee iIIuatration0.24bJ.II removed. Instal the valve 00V8f (Section 8).

Engine, clutch and transmission 2- 15

Ihe lorQUesetl lr>gspecilledat 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<J
and guide blsde can be remoVtJdwjth the engiI)einthefntmot.

Cam chain I Separat .. the crankcase haIvss (Section 24) and ,emove the crankshaft (see Section2n 2 $lip lhe cam c1Wn oIT the crankshaft Inspection 3 Pull the chain tliOht 10 re<noveany slack, theo m8IISUre the O!ogth 0121 pins (ffom the centre 01 lhe 1st pin 10 the ce
thechalnl, repla<::ed,alsoreplacelhe camshaft sprockets (. .... Section II) , The sprocket on Ihe crankshafl should also be chlld<ed {_Section 27). 4 Sup lhe

C
chain onto

~s sprocMet

on the

crankshaft .m aking9tJ"e ~OsproperiyllO(j3ged.

5 InSla11 lhe crankshaft (see Seclion 27)

Removal II Rem:wa Ihe cy!lnder block (Section 15) 12 On 550 models . ,.mov.the lWOOI

~~~;~ 7;~:c'~~~r~:~~~ ~~~e ~::I~~~ kx;al. in their cut-DOts (_ iNuslrationf. 17 1.... taflll>ecylinOerbk>ck( ..... Seclion I5)

::;::~lpioandseparatelhebtadeandlhe

::ns<:n:~'a~:~S·ol"::s I~t.:~ I~h:~~ crankcase.notingwhichwayround~ms ( _

IliustrationIO.I&), Tak"cafeflOtloklsethe =~":""~.pivotshaftwhlctl li!sinIO

Inspection 14 Examine the slIdl,,!! surtace 01 the teroaionefbladeforsigrtsol wea,ordama{l8. and ,eplace it il necessary. Check the condilionol Ih"pivol hardware and ,eplace :r...=~nIS thaI are da maged or

Note, The cam,lIef,..nd followef3 can be remoVtJd wlrh the engine in the f1ame.

Removal I Remove lhe valve cover{_ Section 8) 2 Unsc,ew Ihe bolts s&cu,log Ihe pulse geoomlor coit cover 10 II>e righI-hand !Iide of lhe engine (.... mUSIr.!lon) . The engine can berotatedbyusl"!!a17mmsockelonlhe l;rnirlgrotorhe.andlumIngRinactockwise directiononly{see illusirationf. Caut/otl: DONOT use thetlmlrlgrotorbofl to tum the cnmklhaft -/I may snap orsfrip

~~t;,reo:",.,II~,:,~~e engine In lIs 2 Ihepiottvoogh 10 secure it. Inslalilheblad .. onlO the cranl
Alte ,natlvely. place the moto'cycle on lIS centre sland {wllere filtedj or support it vsir>g 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>ecylinderbloci<..making9tJ"..

2- 16 Engine, clutch and transmission

dirf!Ctiono!rotation , Rotate theenglr>e uotil the T mark on the roto, Is aHgnlld with the

,tatictimin!l ma rk on thecrankcne (5. . illustration). and so thaI the Z5EX marl< (550 mod&ts) or VEX mark (7W models) on IheexhaU$lcamshall sprocket points at the ,al,eco,ergasketmat,ng8urfaceoothe front 01 the cytinoor hoad (SH illustrations 11.248 ar>d b) . Check the pos~ions 01 all tho marl<s 011 the exhaust and inlakesprockets Thisi, how they shou ld bepOs,tioo&d lor InSlal latfon later. On 550 mode ls, as Ihe

~:::~s::a~~~a~aa~el~ ~m:~,\::

6

P ~ II

up 00 the cam ch ain and carefully

;::~~:; :~I,~I~: e~ ':I~O:;~~~o;h~~ ouIol lhe cylOnder head and stO<e lhemin the correspor>dingcompa
from d.oppiog. Also. co,erthe top 01 the cyl indef head with II rag 10 prevent loraign

~t~:::=aI-:":h~"!i'idlld into

eight compartments. and label each compartmem witn Ihe location of ilS

Inlake camshalt (or us. tags or labell) so they cao be "ad i~ identified lor Insta l ~lion 00750modets,lheexhauSI camshalt has a raised section 10 Iha right 01 th"sp
~~:o~;~~P~am

chain lonsioner (see

Section 9)

P.i~iIIll"":'

4 Se/oredisturbingthecarr\shalt caps,check

lor the id"m iflcatioo number on each cap

which corresponds 10 Ihe number mark ed close to il on lhecyllnder head (see illuslralionj.Alsonotethearrowonea.chcap wtli(:hpointo tothelronloftheengioe.These markings ensure that lhe caps can be matched up 10 thei r orig ina l journa ls on

L~~II~III

ins taliaHoo.l lnomarl
your own using a suitabl" lelt pen. If ~;a:~asketchoflhelayoutas "" ~ Unscrew the cap bolts lor """ 01 lila cam!.halts,8V&rI1y and a little at a time and in • r..... er ... of tllatighteoing S&quence (see Illustration 11.26b),until they are all loose

~~~s~:~r~:m~~ ~~~ ~:~s a~ 1:~ao~I~~ camshalt caps , Retri..... e tile dowel . Irom eithef the cap or the cytinOer head il they are loose (SH iliust.ation 11 ,26a) C. ution: Illh. bearing CliP boltJ aren't /oo.$ltfIed_ly, thecsm.h.nmllybind.

corresponding ,atveinthecylindorheadood

:i~~a';"r=":!~~~i!~~hairl.till 1 WMethe camshalt9 111'9 GUt, don 't allow the dIaiotogoalack· thechairo may d'OIl down arld b,nd between the c.ankshaftand case, whictlcould damage the5e compoo8rlls. Wire the chain to anothet componeo! to pre"",,1 ~

11.8b ... arldtheshlm I.om e aehval~

Inspection 9 Inspect thebearlng s u"acesol Ih e head aod thebeafing caps and thecorrespondiog lournals on the cam.halt. Look lor score marks,deep""ratcnes or for any e,ideoce of spallillQ (a pit1&dappeararICe) (s. . Ulustration).

Engine, clutch and transmission 2- 17

11.10. Chec:klhelobes 01 Iheumshsftlorwear -heo"e'a an • • a~oldam&{lerequlrinllcamshaft repairor.-wal 10 Check lhe camshafi lobe. fo r heal disooloralion (blue appearance). score mallis, chipped a reas. rial spotsaod spalling Ilustratiof'l).Measur.lheheighl oleachlobe w~h a mlcromeler I ... e illusl.aUon) and com pare lhe results 10 Ihe min imum lobe heigI>IisledinthisChapler"s$pecificalions.11 damage" rIOted Or wear is . ~ cessi.e. Ih. camshaftmus1berepjaced

I"'.

~!r!:ft':;:~~:u: ~~:'~~f~,: "I'fOC ket mar1
hoIdlngOOllSbelore'&mOVingtheboHsand aepa.ating ihesprockelfr()mlhe camshafi j_ illust.ati()n 11.21a ()r b). Supporleach endol lhecamshah()l'lV-bIocks.andmeasur.

....."runc>UIO)9.Ingad;algaugeposilionedwith Its lipagains11heSprOckDlmounlingshoukler js ... ilius trali()n).lllherunoute.ce8ds ihe opecnied im~1hecamshaflmu$t bereplaced

Install lhe sprocke1 ()I'I Ihe camshah as desctibedin$tep21 12 N e~t. check the camshaft bea.ing ()il dearances. Clean 1he camshafts. the bearing surfaces in 1he cylinder head and 1he bearing caps wilh a ctean. ~n l - l ree ck>th. ther1 Jay the camshaltsin theitcorrecl plac$in1hecytinder head. wUh the sprocket oot heads lacing lhe .illht·ha nd side ()I Ihe engi"" and wilhthe maills c",.eclly alignf!d I.e. IIlust'atl()n 11 .24a and b) . Make Sure Ih. exhaust camshaft is 00 the • • haust &ide 01 the engOne.

and lhe intake camsl>alt Os()l'l lhe inIaI<eslde ollhe engine. E"\Ia{/e the cam chain w~h the spfocketsasyoChbearingjoumal.pa.aU.'wilh 1hecamshaftcentret .... tsee lllu.lratlon) 14 Mak ....... elhecamshaftcapdow... s 8l. inslalledl... IIILltltratlonll.26a).lnstalllhe caps in their correcl numbered posiIion.and wilh the arrow on each cap pointing to lhe Iront 01 the engine l_iULItIlralion 11.4) and Install the bolts. T'q>1en the boIts--.ly and a lillie al a \ime in the sequence sh()wn, 10 the torque ~. ted in Ihis Chapler's Specn""'tion.

~ :~=:;';~!=cIoO>gtNS. 15

N()w

DO

,,"screW lhe bolls. a lilll
andcarllfiJltylifloltthecaps

16 To delermine Ihe oil dearanc:e. com par. the crushed P'ta$llQaugejst itswidesl poi"') ()l'leach)oumallolhescal\tprin tadonthe Plsstlgavge container illus tration) Compa.e Ihe .es ults to this Chapt\tr"s Spec;t"""ions. II lhe oil clea.afICe is Qf. ater Ihanopecillf!d,musure lhediamltlerof the ca m bearing Purnal with a micrometer Is'" illustration). If lhe iOumal d iamaler is less

I'"

2

2-1 8 Engine, clutch and transmission than the specitied mt. replace the camshaft wltha.-one.-ldreeh«:ktheclearance.tl theclearancalssliltoogreal ,c.ifthejotmal diameter .... " within ~mlts. rep\aca the cylinder head and eamsh.ft caps with ........

""..

~

S.foN

~1nfI

camalYlU

_

fNIMC)'IndwhMdandcapi

I

Hea.,.. with

of~, c~.

~I

machine sIIopa

~"'-~engIne-'<. "'tfIe _ oItf1e~ltmaybe

ponIbM fw

'*" loON to t» ....u.d, ,...

grrwntl and

h~""

at a coat far

10_ tMn ,INt of a new CMMIIaft. If tfIe bHrlng .url_ In th. ~ 1IeMI_~ltllY)'be"""""

fw , " - '0

t» boNd

0411 to acc:ept

~~Dueto",.COItolaMW C)'IrxWhMdlt,.~~

..

optfoM ba 81IpIotW ".,.". condIttnINrIg 1t .. 1Tuh1 17 Except In casea 01 011 starvation,thecam

chsin waars vary little. If Ihe chain has stretched beyond Its limit (see Section 10), which makes it difficult to maintain proper tension,replacehwith a..-one. 18 Check the sprockets lor wear, Cl'3Cks and other damage. replacing them if necessary. If the sprockets ilfe wom, the chain Is also wom.andalsolhellPf'OCl\elonthecraokshioft (whiChe&nOAYybe......adiedbyreplacngthe

crltnllshaft). If wur Ihis severe Is apparent theentireenglnethouldbe~for

Inspection. 19 Inspect the outer stJriaces of the cam followers for tvldenc. 01 scoring or other damage. If a follower Is In poor cond~ion. ~ Is probabl e that the bora In which it works Is

also damaged. Check for clearance belw.., the followerl.nd thel. bores. Whilst no specifications ilf. given, ~ slack Is axcesslve, reptace the followers. If the boras are seriousIyout-of-roundor tapered,thecytinder head and thefolowersmust be replaced.

Install.tlon 20 LubrlcateNdlllhimandilslolowerwlth &nglne oIl.nd Install them in tl\e cylind..

head,noting lhaltl\e shim must beinst.11ed with Ita alze marking down.... ards Ina IIlutlr.tJon. 11.8b and a ). Note: It Is moSI ImporTant l/lal Ihe shims and followers are relumedlotheirorlfJlnalvll/Yesolh8tw/selhe val\lecleallrnceswUlblllnaccurate. 21 Ifrtn'lO'led,lnstall each sprOCket onto Its camshaft . The sprocketa are identical and can be Interchanged, but are installed using diff....,t mounting holes ISM Illu. tratlon. ). Be sure tOcorr8Ctly Idenlily each c.mshaf! ( _ Sl ep 2), then 1r\$\8lIII\eSprockelS IoCcordlngly. M.ke stJre lhey .re installed COIT8CIIy.nd ....lthtne marl<ed side Of each sprocket lacing out Olherwlse the timing m.rks will not .Iign. Apply a smear 0 1 a suit.blt non-pennanent Ihread locking compound to the sprocket bolls. then Ntall II\am'ndllghtantl\am loll\elorque$llling specified at the beg!nnlng of the Chapter. 22 Makt surt the bearing su rlaces In Iht cylinder head and Ihe camshaft caps are clean , then apply I light coat of engine assembly lube or moty-based grease to each of them. Apply a coal ofmoly-based grease to thecams/laftlobrn,

23 Check tllat lhe cam chain Is engaged around the lower sprocket teeth on the cranksh.ft and thai the crankshaft It poeItIoned as described In Step 2. Next Identify wNch Is the exhaust camshaIt and..mlch Is the Int.ke (see Step 2). Install the e~lIaus t camshaft ttvough the cam chain. Pos/tIon ~ 10 tMt theZSEX mark (550 models) or Z1EX marl< (150 models) on the sprocket poinlS Iorwarda and Is nushwith the lop of the cylinder head mating 1Uff_ ( _ iIIustntiona 11..2Aa and b) . I(eeping the front run of the chain taut engagethechalnonthesprockelleetft. 24 Starting wilh the cam chain pin t"'llt directlyopposlletheZ5EX mark (550 models) ancIlIIgtrttyllboYethtZ1EXrnark(150modeIa)

on the al
2:5 aefOfe proceeding furth.., check that averyI/Wlglignsas described In Steps 2, 23

11.248 camsllafttimlng detaiIs-SSOmoOehi

ZSINmarl< 2 Sprocketbolts(lntskeJ f

31ntaJceC8fJl$haff$plOeket

4 CamchB/n 5 CylinderheadfOlllslret

'""~

6 ExhaustC8fJl$haffsptOCket

1 Sprockelbolts(emtusti

• Z>EX_ 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 <:fV
cams halt cap dowels .ra inltallea (s e . IIluslrat i on), the n mtlle~a ptl.ma k i ngsu, e

lheyarelnthoeirproperPOSi!ionsunotedon removal (Step .) tHe illustration II .•) Toghten tn.. ~ap OOIS on one ~amshafll!l'lel1ly ony turning the efankshlllt a lew d-egrMS in each direction with a 17 mm socket on Ihe IIm lr>g ,Olor h.. (.... IIlustnltionl1.2b). Caullo", If tha mar1rs are nol a llg"a d uaCllyIJs descrlbed,ll!avalva l/mlngw/U be~IIJndltta ..alvesmaysfrlI<e ll!a pislo"s, cau'lnge"lensivedlJmage loll..,

.....

28 Install the cam chain tensloner (see

Section 9). 29 Ctl8d< IM valYe clearances( .... C/tat:lI... 1).

3OTher(llTl&lnderollnslaitalioni.the.-01 removal Apply e sme ar 0 1 seal8nt to tl\e cran-kCllse joinls on the pulse oene,atOi asseml>ty caver mati ng s urface {ua Illuslntllon9 .2 4a).lnstalilhepo~ oeneratOf

assembly COver uSir>g a new gas ket and

tightanl1sboltstotn..Speclfoed\0n:!U8H11lng (_~lustratlong.24b) . l ns talil heyaivacover

(see S8ction B).

12 Cylinder head -

removal and installation

~

2 Removatn..e>
:;~r:!s~e~w:: f~em;,~~n::S~~~d~~:

~ :i=.~~~:,~:~=~~::

Ca ulif"" The ""g/"e musl be comp/el~ r;ooIbMorabegin"lnglhlsprocaduraMlha

~!~~:8~~b~~ (:~ ~~~:,~~n~r

lha engina lnl/la frarN.lftlla e""lnan.ts

klentilication ts ... IllustratiOn). Sla~ken the nutsevenlyand a littill at atimtlina ... _ 0 1 tIIetr """""W;aI uqu""",until they a.. ,II stack. Remove 811 In.. nulsand IheO" washers,

8iJwdybean~,~""$repswl>ich

::~enottodrop8nyoltheminIO

cyIInderlludmaybecomew~

Note: The cyJ/nderhMdCNIberemoved wilh

don lapply.

Removal

6 On 750 made ls, Ih' cylinder head ~ s ecured by Iwelve 10 mm domed nuts wit h

1 Rllm<>velhecarbumttors(seeCNpl... 3).

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

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

.

~

~ ~- ~. ~t.-o ·<~~ .;

'1 _ _ 0

_ra.o~'\.ok ...

~~

~

-

.

Remove the cylinder head f,onl boi" (A) and cylinder bk>ck nut (B) .. I~Sa

!.

o~\ ~

I~

=0

'-j

-

t2.5b ... and the cyllnderhlladrea. bolls (A) and cyllnde, block nul, (B)

2

2 e 20 Engine, clutch and transmission

12.5c Cy1lndefhead nut TtGHTENING sequence - 550 modell

"""nul,

chaindowfl tlvoughlhe tunnei as you do . Do not lei the chain fal into the bIocI< - SoIiIC\M"eil

located inside the cam chain tumeI. andbolts_runbered forideoti6catlon (see IthJ'.... tIon). Siackenlhemevenlyandllit1te at a lime In 1 r everlt o! their nUmefk:al sequenceuntiltheyareallslack.R8!TIO\Ieali the nuts Ind their was hers. and the bolts. l aking greal ctlre not to drop lltl)' 01 them Into thecrankctlM 7 Pull the cylinder head up oil the Itudl. If ~ Is stuck. tap around the joint lae.. 01 lhe cylinder headwrlh aaoft-Iaced mallei to ITee the head. Dono! attempltolTee thellMdby

from doiogso. Removelheoldcylinderhead gaskel and the twooll nozzles.nd the O-rings which III around Ihem on each . nd 01 the btock. Stu1facl••nr.g Into the c.m ch ain tunnel to pi"event any debris falling in to Ihe engine. Ols.card the gasket and O-rings as

insertrog.lCreWdri'Ierbet~theheadand

lleilherappearstobemissingili5~obabty

cylinOerbloek-you'lidamagethoesealing surfaces. 8 U/I the head ofl the block. Pilssing the ctlm

sh.ocI
withap;eceolwnormetaibartoprwent~

new ones must be used. 9 If they are loose, temO\Ie the dowels from around the front out.-Ituds 1_ ~lu stnoUon).

t 2.9 R8fTIO'Ie the dowel (.rrowed) from each fTonl outer.tud if it la 100M

, '.

f' ~

Installa tion 12 IIr8ll"lO'ied.nslailhetwodow!!lsootothe /Jont outer.tudl 00 lhecytlnder block (see Wtu. tnltion t 2.9). lubricatethecylinderbores with engine oil. 13 Make sure the 011 nozztes are clean and notblocked. thitninstatllhem Into each end 01 the cylinder block (see ltI u. tration). Fit new O-rings around them (see illustration). Make sure Ihey are po-essed into their recesses and are property seated. 14 Ensurebothcylinderhe.d.nd block mating IWrfac8$ lire CleM. then lay the new heedgaskel lnplaeeonlhoecyl;nderblock. making sure aI thehoies are correctty aligned and that lhe UPor HEAD letters 00 the gasket tace up. Neverre-use t.... oId gaskel 15 Carelulty Iowltrt.... cylindltrhead over the stlld:sand ooto I"" block (... Illustration). It ;'helpful to hi!ve an.SIIlstant to pass t.... cam chainup!hroughihe turYl8land slip a piece 01 wire through it 10 pr......,t it falOOg back into ihe engine. Keep lhe chain taut toprftYMtt it becoming disengaged trom the crankshaft

..-.

"-

~.

block for signs of Ie.kage, whk:h could Indicate warpage. ReIer to Section 14 and checktlleftatnessoltlleeylinclerhead I I Clean all traee. 01 old gaskel material fromlhecytinderhead and block. lIascraper Os used. lake care not to scratct1 or gouge lhe soft aluminium. Becarelul not to let any 01 lhe gasket material 18111nl 0 the crankcase. the cylinder bofes or the oil paasages.

'

,

~ I

..

.. • and fit .newO-ring aroundil

12.15 Keep the cam chain taut wMn Iltting the cylinder head

HI On 550 models, install lhe twelve 10 mm domed nuts with their plain washflfS and tighten lhem linger-tight. Now tighten the outs evenly and a littleat . lime In their numerical saquence (sea lIIullr. lion 12.5c) to the torqueseltingspeciliedet l hebeginningol theCl\ap!er (see Nlustnotlonl. When tile nuts are correctty torqueci. tighten the bolts at the /Jont and back 01 the cylinder head.nd lhe nuts at the Iront and back 01 I tlecylinder block 10 thespecilled l orquesetting {see il lu stration 12.5a and b)

Engine, clutch and transmission 2- 21

~ ...... -. --~

-.-

....... ~"'<1

!

~

:- -

11.10Tlg hlen .... ~_nuUoln .... COffK1~IO""epedIIed~

17 On 7SCon:>OeIs, ..... t... the twelve 10tTnl domtdnutlwithll>eirpt8inwaa/lerl,aodlhe 1w08mmbo/lsaodtightenthemfinQet'-tight Now Ilg/1 tenlhenulSandbo1l"~Bnda

litlt" 1 a lima inlh", nume,lcatseq\llll<:a (_ ltlultr.tion I 2.0) lolhelorqueselUngs lpec/llldillhel>egimngollhe(;/\apt« {_ .ilk4tr1otionl2.ttl) t lltel ....... canshaflSItMSectionII)_ 1he_~(MeSoction81.

,, 1ntl8llhespar1
20 Insl8l .... 9l
guide.eplac.".,.tlhouldbelento. Kaw.sakl deliI.-. Howe>t .... d;aassernbly, cleaning and IMpec:tion 01 lhe valYn and relaled comPQf*11f can be done 01 1M necessary"*""too/l ... avaitablelby .... home mechlnic. This way no IXpen. . " incurrOKlHlhelnspectlonrlYNlsthitoverhlul isnot'equlred" thil timot. 2. To dlsa,sembl. lhe valve coml><>/1.nl • wilhou1 the ,I.k 01 damaging them,' " .lvl springcompreu.orisabsolulely_lIfY. This sp«:iaI tool can usually be ffInIed. but ~ iI·'not .....bIe.hlv• • deal«HrVk:. dlplftmentOflnOlOfq'dlrepairshoplWldle lheenlireprocMlo/~.~.

=:,,:-(Hr~andreasaernbly

Disassembly 3 Blior.proclldlng,.rrangelolabll and store lhe ... al"" along with lilli, "".Itod compOnef"ltslnllUd"l.waythallhlycanbe "",.. fIfKII01t1Woriglnallocatiorllwithou1 'lilting mI.ed up (1_iIIUI' •• 'ion). An • • c.....·.. WIY 1000 !hie is 10 make up e conI...... which is dMded Into elgh1 compartmenll.lndthlntollblllachwllh theld.-ntlty 01 thll ... Ilve and component. which wl. be ' Iortod in il (ie Ihil numlll< of,t>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.'bondepos
hlldwnbrushOflp;.c.oIflneemerycioth c.nbeu""",,oncatn.majorityoldepos
__

-VOfscralchedby

5Compr'e$S ........... ~"" thlfirslvalve w~ h a Sj)r"ing ComPlIllor, malting s u'e il I, corrlCtlylocattodonloeachendol lhe "a1 ....

assembIy (uelllul trallon).OonotCOl"J"il)rMS the eprlngs Iny morl thin II absolutely tIIoClIIIIY. Remove theco/lel., using_ nMdle-noM pieri. twMl. ., I magnel or a scrlWdriv« wlth I dab 01 11'1. .1 "" " 1_ 1IuotratIon). c.eUy . . . . . spmg compressorandremoYlthlapr!ng..wr-.

thI_

noIlngwNchWlyup~lb.lhe~andthl

Vllvefromthehead l_II"'''ltionl ''.21c, b and I). II thlvalvllllndsln!hegulde(won'1

13 Valveslvalvesealslvalve

guIdes -servicing l Becauseo/lhec:omplu ...llIf'oI~job and .... speclaltooIsand~raquiwl. mos1 own... " ..... SWYicIng 01 IhI v.lYn. "......_,saodvalveguidestoaprolesslonBl 2 "Th1hom1lT11C1>anicc-.._.remove IhI".lYnfromlt>ecytindlrflead.cle,nlnd checl! Ihe component. lor wea, Ir\d .,sess Ihlex!enlolthl _ _ .... ,. ........ lcel.fIQO~IId.Qrindinthev.,." (_Sectiont,,). 3 "Th1dM1ers..-W:e
-.

2

....... ......,.aperaIionLlIMcomprIIMd • . illv.w.~,toblowou1allthlholHand

1.C.ylinderhea~andv.alves -

==~Iy,mspeClionand

~ ~

, ,..mantionlldinlhe"......,.,.MC1Ol.v...... ..,...;cing.".... e ..... I"'-cutting.ndvlllve

".3 Valva oomponenb 2 Shim

'm-_ 7Sr"",SH/

3ec.r.ts~8Spting_1

".Sb R_thlco/lebwlthrwedla-

• SptingIWI.... ~ OuNr.spofrlg

~wtth.dabofor_onll

9e.n.ustllfNl lO .. fa/<e .....

_pIien,_z_ .....gnat or .

2· 22 Engine, clutch and transmission

coIet....,.,.

, • .5c H tIM ...... . tem_'1~througihtIMguIde,deburrtIM .... _ . tIM ..... ttIe_

IldIlIw'ough).pusI'Iitbad
wirlbnJlhlO_~fromthe

deblA'Tthe_8JOU'Idthecolet~with .~mefjeorMlel$lone t_illusll;>tlon)

_1fId1l ...... ,e,g.ln.meke ..... do not get mixed up.

II Repeal tl>e p
Inspection

_.~lOkMptIMpartsklr
;==~~-::=~~ thllycan be

h.".

7 One. the val". . been.emove<:i and labeIIod.pulltheva""ttmsealsolittle topof Iheva"'Q<.IidMwithpilersand d iscardthem (theoidseal.shouldnev&rbe.eused). lh8r1 removetIM~_Ie,lIOlingwhichw~up

theylit t_iIIu5tnollon. ,4.2et\...,;I e) B Nell.clunthllcylinderhndwithsolvent and dry it thoroughly. ComprHsed_wili

:==:::IhaU. 9 C!ean"ofthevelve.tpring$,collets. .etainenendaprinQ_t.withsotventend dry thIIm thorougllly. 00 trMI parts from one

::: ::::':::'~t no

"';Klng 01 part.

10 Sc.apeoU Iny depo,..lIs that may have formed on thll vaivi. trMIn use a motoosed

I I InsplCltlM hNd~cerelUlylorcracl<s andothet dlmage.llcrackaarelound.I'I"Ieedwillbif"«lUired.Cl>llCktrMIcamlllaring

""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$OClionlor dll.11I of how to chI<:I< for use • straight. -'1/1. II thehud;' werped. it rooste/lher l1li machlnedOt,lIw'~'-I>lClS$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..... ltIdillguidtlintwope
Engine, clutch and transmission 2- 23

14.1 6C"-ck 1he valvef&cflW,tte m (B)and collel llroove IC)for aillnl olwear enddam"ll" (at both eods and the centre of the guide) with a small hota ga.,ga and mic,omete< (Ha iliustratiom). Thtoguid8ll ...... """"""edalthe ends and al thecenlre to determine il they ...a wom In a beU-mouth pattern (more wear at the ends) . If the valve stem or lIuide Is worn beyond

~s limil. ~"..".I

be replaced

15 Csrelully InSp$Ct each valve lace for cracks. pil5 &rldbumedspols. Meas ure tha valve lace thickness arid compare ~ 10 this Chapler·sSpecijica\ions (SH II' ustration). ~

il e.ce&ds Ihe seNice limit. or If il var>to. arourld Its clr<;umfe<ence. valve overhaul Is

~klhe valvestemarld lheCOliel

g,oova a,... forcracl<s (na ill us tratio n)

..

~th:~~t a:,~.~~~n~~,: slem lor pittir>g 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<;hvalvaap,lngfo'

ITI ~ TI ~I ~ 14.17 M. .sur. the valv. et .... runout using V-blocks and a dia l gaull" as s hown

14.1Sa M......... the fr . . langthofthe valvespr\nlJ&

2- 24 Engine, clutch and transmission

byple<:ing ......... ~~ I_ilklstrationl . " .... bendlnll'l)'apring.excessivoe.~mus'

~-. 18 Chldclheepmg.~Wldcolletstor obvlou.w....flde'eck •. My
-.ThIt~~CQIII"5OIanclrw.. V"'IJIhinIl~IndI'lfllole1Jlhinll

tool.HIgrlnding IOOl .fK)I.vailable.lpiIce oIrubberOtp!as'IcIloMCIIlbe$lippedOYll" thl V.,.... tam (aUer Ih. v.'wo hIS been

~~inllM""Id.)'ndUHd IO I..nthe 22

~I_R....-.ounlofCOll"Wgm.:mg

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 Atte<:h Iha!lJlnc:Hnll '001 tOt OOse)'o Ihi v..... ancI belweM the paIrm 01 'fO'J'~.UM.~·ancI·forIhmo!lon(.. Illoughrubblngyou,IIands'09I'heo").a' '''' lNinaeircularmolion["'soltlal thl v..... aI,.....,1Iy d<>ckwise and anti· clockwlHrathlrth.,inOllldire<:liononlyl t_ Ykdtr.tlon). un .... valve oft Ihi SUI ancItum~.reg<.W"lnt.....atodistribull .... grinding compound properly. Conlinue lh1 grlndlngprocedurluntU'hlvllll"a<;_and HI'conla<;tlreaiaolu";/ormwidlhand unbrokIn ..-ound Ihl circurm.ence 01 IhI l_ancI_' (... K1usu .tIon) eompoutKI

rotI,. .... ''''''

roll'"

v"""

.,'ir,

2.( ~~the ...... h'omlheguidl Wldwlptaft .. tracesol\P'"dingcornpGl.O"Od. UHIOIvtn"oclunllleva/vaandw;p. ,he :!."HlhoroughtywtthasotvlII'_ked

v_

25 Repeat Ih. procedure wilh Iina .. a lva g,'ndlngeomPOOnd .tl>en ,epea'thaantire procedure lor IhI 'emaining

2e lIythalj)riogseals loralilha"atv"1n ~ecl in ,lie eylindar head wilh thlt, ~tOdallOCingupsothattheylilint o .... lMHoIlhe~{lhespring_Cfllllbe

Idenlilledh'om .... lP1ngretainerby~~ 1nMrnaldiamet«·be .... fK)Itoll"Uup .... IWO), , ' - tn.tan IIIW ... Ive s tem _ I . on MdloI .... "'""'* I... -..,;IratIonsI.lIH . . .".,..O!)rI.telizldeepsockll,opush'hI . . . OYII" .... _ofthevalveguidl...c~they

. . 1eIt'o~lmopmca. Con" twistOtcock tham,Ottheywilnot,ealpropertya.gaimllhe v. . . Il....... AIIo.don'Iremovettlem~Ot theywlllbld~.

Engine, clutch and transmission 2- 25

21 CoatH>evalvest&ms withmolybd&num disl.Opl>idegrf)a$e. U>en;ns1all one of 1I>em Into ~S guide. roIatiog it !\lowly to avoid damaging t ~seal (se_ lllusteinneei'cIo_wour>dcoi~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!cyMdMbIocI
Re m Ollal 1 Remove Ihecy1inde< Madlsee Section 12).

~~':'00'::,= ~:~~"!=~~~:~

""""'ca... Sluds. 2 l1oIdlf>ecarnchain 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<WfI<'Il illromoo;ng so . llthe biockissIUCk. lap around the ....... t laoes of the bIocI< with a soft-laced maKetto Ir" ~ from lhe ctankcaM. taking great care rIOt to damage any 0 1 lhe cooIIngftns, [)onl anempt to"," the bIocI< by Inserting a scrllwd rlverbetwMn ~and t he crankcase _ you '" damaQe lhe Mallng suliaces.Whllnthllblock isrllmoved,Slull cleanragsa,oun(llheplslonsloprevenl

~------~ ~n~~=:t~~an:'~GI1118Ch ~ C"ee~lo,proper"alingOf

~ '::v:,:V:O":::,"~n,~~~~

~-.:-r::.::,::~re::=

""Y ..... ~ ..wegrttdlngopenollon ()(IllIar ~...... sItouIdb\l""",,'ed.

L -_ _ __ _ _-----'

~~nk~~:e R~~Vem~~n~o~~~~c~nt~:i~

~~=::7~~!tOscard

IheO-rings - R&mOve lhe gas~et .nd, where 8 paperbasad gasl<eI has been used. clean an traces ofokl\i3Sketmatooallromlf>ecylir
Inspec tion

s

Do nol attempt to $9I)arate the cyllndll' Ilner$lromlf>ec)'ilndarbiock

:c;~ ~~ ~~:~ar:II! =~~II': neeessary to,~anydeepscor8S

7 Noligure i. given lor block gasket lacII warpage , but a check can be peli()(med as d\lSaibedI()(thflcyliodeSS/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"""" lhecyllnde
amount 01 wea',laper and ovality. M""su,e ne .... the top (but below tne level oflne top pistooringatTOC-aboull0mmt>elow lne lOP 01 lne CytindM). ceolre and bol1orn (but above the levet 01 the 011 ring aIBOC- aboul 2Onvnabovelheboltomolthecy1ioder)oIthe bofe, both para ll~ to and acron the cran~sha lt axis (0'" Illustration) . Ca lculate any dif/llfeoc ... betWe8f\ the measurements taken to determinflMY tapfIfand ovality in lhe bo<e.Con!parethe,esultstolhespecl1lcatlons at thebeglnnlngollheCllaptllf,fflhecymoers O{etaperad. oval. or wom beyond lhe senoIc9 Iim~s , or badly scratched . sculled or scored. ,,"velhernreboredandl>onedbyaKawasaki dealMorbi keenginea,lngspeelallSl. ll lhe qWldersBM~ . l heywi~ , equireQV9rS i ze

pislonsanc:lmgs 9 11the p
bIoc ~

and cylinders life in good

condrtionllndthepislon-tc>-boreclearance~

w~hln

speelllcaHons ( _ Sscli
II Hold the block Sideways (so thai the

bores 8J'9 horil:ontal ralher than vllKticaljin a sott jaws or cushiooed witllwooden blocks, Moun t the hone In Ihe drill motor, COInptMS the Slones and insert tt>& honfI Into theeylinder.Thoroughtylut:Cesa llr;ec ,oss-hatchpaU... nonthe cylinder wall with the lirl8S int ... sec~ng al an a"9leolapprOlllmately60·. Se sure 10 use plent)' 01 tubricanl and do f>Ot take 0 11 any vice with

:'~.::::.nr:

;;"e;'::::: ~od=

I romlhecylinderwhile~isslillturning.Swi t ch

ol! the drill and conti nue 10 move It up and down In the cyli nder until il has slopped lurnlng, Ihen compres. the stones and withdraw the hone. Wlpa Ihe 0 11 !.om Ihe cyli nder a nd repeat the p.-ocedura onlh, ot herc~ li nd .... Remember, do not ta ke too much mal& cylinder wall 12 Wash the cylinders II>orovghty wilh warm s oapy water 10 remove all traces o! the abrasiva grit p
14 Check that light in

a~ the

tl>&cr"""case.

cyIir
''''''''''''

them, noting which Irts where as they ale 01 dill ... enllengths, than clean th ~r th'ead, AppIyasuitablenoo·permanent ttyeadlockJng compoundandtightenll>emsecure!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 corre<:tly al>gnedand 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
~=~:;::::,:,,~istant 10 suppor1 lhe

Engine, clutch and transmission 2- 27

15.19 Mak" urelhepillon&enterltleirbores oquarely Ig Lubricat 'the~inderbofe • . pistoosand pistoorinQs. and Ihe """"""ting rod big and

~aJ=. d:i;:nC~ e;'~e~t~:':t:~~t~~ uppermost piston crowns lit into the bor". <.... Itlustr. lloo). At tN. $tage leed the cam chain up through the ~oc~ and secure it in plac" with a piece 0\ wi,,, to prevent rtlrom latlingbackdown 20 Ger1l1y push dOWe block

15.20 Pass ll>ecamchalnUlllhroughlhebkx:k

16Pist~n$-removal , inspectiOf1 and tnstallatton

~ ~

Note: TIl
Removal

~~.~=~~=!~~~~~

!s e e iliu s tr. tlon) .Pushlhe pislonplnoul lrom the oIher side 10 I'M the plstoo from the connecting rod (_lIlustratlon)_Remov.the other c irc li p and disca,dth.m as n...... ooes , -_ _ _ _ _ _----, ~

To pnlvell' Ihe c;rcl;p from

! =e :~~t~~i~n~~~:~ ~ ~,!t:~~:c~:::£~ :;::Ii~"~od$~';," ~=1 r~eOt~~r~':~

anything IIls8 from laDing Onto It>ecrankcase \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 bylhelelle
S8C1Oons/"lepe l_

lnustraIlon17.11b)

II Scr_a" !racesof carbon fTom tl>e tops 0/ tl1epistons.Aha~heldwifebrushorapiece

01 fiM """")' cloth can be used oocemost 0/

markec:lonlh/.lpisloniscleanedoff.bttsurato re-mark~withtl1ecorreclkk1ntily.MBkesure

~~tum holMbeIowtl1eoilrir>ggrOOV"

8 Ca,elulty inspect each piston lor cracks around Ille skirt, at the pin boss8s and a(tl>e

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>g In it5 grooveand..upping afeel&rgauge "' beside~ (.ee ll1us lra llon) . Make sura you havatha

~~~~",:~~sae~.=

tile deposits hava been sc raped away. Do

;:~~:~~n~~ ~;~u~~:la::~ ~~ar:.,:i;: depoeits Irom the pistons; the pi$ton material :u~ft and will be ",oded away by Iha wire 7

U sea pi s (onnr>gg,ooveclea~ngloollo

,emova any carbon deposits from the rlng grooves. Ila tool Is oot ava ilabla. a pleca broken off an old ring W"III do tl1ejotl. Be very careful 10 remove onty tl1e carl>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

Engine, clutch and transmission 2- 29

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&
~~ :E~~~~:.:~:r~v~

op ... allon, file only from Iheootsldeir1 lse, Illustration).

l lt l.goodpractl~lo

.. plac' thepi",on rings when I n engine Is beingoverhaul&d Beforeinstal i ngthaMWpistonnr.gs.ltJeriog end oapslT'OSt be check..:!

6 Excefls "oo gap is nol critical unleasil;" g real",'hanO.6 rrm. Agaln, doubl& cl>eck to make sure you nave the correcl rings for your &ngineandcheck lhat ti ... boreisnolwom

7 Repeat the proeadyre lor each ring lhal will b,'nstlllled In the cylinders. Remember to k&/1PtMriI'Igs,p;stons endcylindef5matched

",

ao"", t ha ring end gllfls halla bean checkedlcorrected, the rlngscanbelnstalled on lhe pistons 9 The oil cont,oI ril'lg(lowest on the pistonj ia ins t~ l ledllrs!. niscomposedofthrG&s&p8fate componants, namely theupander and tt>e upper and tow ... side ra~s_ SHp the expander intothe groove. then install the upper .i<panderandlhe'ing Iand , HoIdHfirmty in pllICe l1l"
2

2- 30 Engine, c lutch and transmission

17_lla Note the letter larrowedj which must lace up

17.llb Compr"~";;:t~roSS-M<:UOM ITopring

r>eatlheendO"llisfacr.oup,Fft th<'lmglnlo Ihemiddl&~ln thepiston.Dooote,..:l8Od

theringanymor.. thanisnecessalY

17.IIC compre;::;:';:I~ro5S'M<:Uons ­ A Topring

2Secondring

"".t. Ma k_ su", that the id"ntilication leiter l o_~

i nto~ace.Toavoidbreaking l hering , usea

piston ring Inslalaboo toot. 12 Flnalty.lnsta ltlhe toprlnll ln1h .. same manner into the lop goroove in th<'l piston, The top ring can be in1JtBlIe<\ e;lher wWl up 13 Onc" the rings are correctl y Inst8118<1, clw:k they move IrMty wrthoul snagginO and stagger their &old (;apS U shown Is" lIIustn.tion) .

8 Secondring

C -N"marl<

3 FrH th" pulse g_ratorco;l and oil pressu, .. s wilch wiring from any clamps on Iheclutchcoverbolts.notlngltsroutir>g WorIingp'epar8
:~'::::~:)~:;tt:::

:~::hasat';!.=u:~~~~ t~ gasket and discard it. Remove Ihe Iwodowllls :':'~herthec""*'Otthecrricase.ifthey

4 WorI
17.1 3 When ,nstall,nllthe nnlls,stallger lhelrend 1I"ps as shown

18

~~n~t~rl~~~al, inspection ~

1 Toprirlg

2 Second ring 3 QI ringsidll rails

"

Nole : The clulch can be r&m<>.&dwilh II!e angirIeirll/l/llr8me.

theringisOdelltili8
and""".,ty sl eck".,theclu l chpressure~a t e

bolts unlil sprlng pressur" IsreleaS&d I"" IlIust",tion) . Removelh<'l boItsaod springs, thftn withd raw the pres.ure "",Ie (5 •• Illustrallons 18.21b and al. Remove the rel .. asa rod. and on 750 models the thrust wasllerand rlll ....... t>earing. lrom eithllflhe backol t hepressu
Remove'

inp<Jt shalt (sea illus tration 18.20) . On

I Dmin th<'leng .... oiI(re!ertoChaptert) 2 Disconnect theclulchcable(Sectiont9. Sl"lll).

theprusureplateand ,emaln$tl'H>reunle ... 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 h<'l rale asabeari"llisfiltedinto

18.3bClutchco... rbolts (arrow..:l)-750modeIs . Note thftpos lUons oflhewlringclamps lA)

Engine, clutch and transmission 2-31

I Innerrh/ll~r washer 2 Spacer 3Needlero/lerbearing 4 Clutch housing 5 TIlrustwasller

l' Release rod 7 Fricb·onplates

:::::tes 10 C/ulchnul

S Grasp the complete set of clutch plates and remove them as a pack. Unless the plates are be;ng replaced with new ones. keep them in their original order. II Ihe plates are being separated. nole that on 550 models the imetmOstplalnplateisthicker thantheOUIer ones, and on 750 C5 and Ot models the innermost and outermost friction plates differ Iromtheresl.

12 Relelis8beaJing(bal/type)55OmodeIs 13 Re/easebeaJing (needle type) -75OmodeJs

6 To remove the clutch nut the input shalt must be locked. This can be done In several waY5. II the engine is in Ihe lrame. engage 1st g.earand have an assistanthotd the rear brake on hard with the rear lyre in finn conlact with the ground. Alternatively. the Kawasak i service 1001 (PI. No. 5700'-'243). or a simi lar home-made tool made from two slrips 01steel bent at the ends and bolted together In the

A clutch CitIItni holdlnfJ '001 can easily be made using two strips of~teelben'o .........t t""ondsiJlldbollftd tOflflthfKint""midd/e

14 IS 16 17

nwsl WWHN - 750 models Pressureplate Spring Pressureplatebolt

middle 1$88 Tool tip) , can be used to stop the clu tch centre from turning whilst the nut Is s1ac1<en&d (see illustration). Unscrew the nul and remove the washer lrom tile inpul shatt. Discard tile nut as a new one must be used 7 Remove tile clutch centre from the shalt, followed by the thrusl washer (see iUustratlons '8.18band a) 8 Slide tile clutch housing off tlleshatt. along

2

2-32 Engine. clutch and transmission

wilh the.-dte ,oller bearing arw:l spacer 1Illust.ations 18.17c. b and a). Also remove t heln~ r th.ust wash ... . notin-g which way round~lits l _ lllu$lratlonI8.(8)

Inspection II Allerane.. tend&dperOodoIS8f1lice tl>e Clulchffictlon ptates will wear and promote c!ulchslip. Measu.e the thickness 01 each l.ictionpt.le usingavernierca liper (.... illustration) . II any ptale has worn to or beyond the $(!(VOc' limit. givoo in the SpecJlications at the beginning 01 the CI>ep1 .... lhe lrictionptatesmvst be ,&pfac«l as a set AI.o. if an~ of the plates sme41 burnt 0' a.e gtazed.thflymust bolr8pl3C
warpageusingaflal ....-laceancl leeleroao..9""

(s e. illus tratlon) .llanyptate e.ceedSlhe rnaxmtJmpennisslbieDlTlClUntotWarpage.or shows$lgnsol bluing. a! pia'" ptatesmust be

replaeedasase1

"

Me8surethe f r~fengthofe""hclutch

springusinga~ca,per l _ IIIUSlratlon)

II any sp'ing is below Ihe see edgeotthehoYsingwithwhi<:hth"Y""IIage.

Similarly checl< lor wear

betw~n

the

In~r

~~~::t~7~:.':I~sa~t~~c~= clutch d.ag AAd slow di--.gaQ&mOOI duoing II""'char>ges.slncethe plates wilsnag wtlen the pn!Ssureptate is lifted. With "",... small

=1~::'~~ t:=C:~!~

components should be replaced 13 Checkthepreaueplate. ,e!easet:>ear'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.

' 4ChecI
operation and any aigns 01 wearordamage. H 1t>eshaft~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 att
~~t;,eo:~~: :~:t~:~,O~~t~i~~h: ~~~~~~~~!~:a:t ;:"'~~~~~~~i~~W:~~t:::h on the 18 Slide the thl'\lst wash
lhen Install the clulchCflntre. making sure it iocales correctly onto the s hall splines (see Illus tratIons) . SlkIy<1d on """"val 10 ptevenl the Inpul sha1t turning. Ilghten thenutlolhelorqtJesettingspecifN!d at Ihe beglMlng of Ihe Chapter (5n IlluSlrallons), Note ,Checktllat rll
(:: I~~~~~~~:~~

I"'"_ _ _~_""~

th ic~ er than

the rest and must be the firs t pta
2 - 34 Engine, clutch and transmission

.

,

";: J'1,..

,,\.

..

-'~'.

1"

~

,.'

~,f' $f)rIng1.ndboltl •.

20 Lubricale lhereleaselOd...-ithrnolybderun disulphidegraase. On 750 modeIslubricale both skies o! the release baaring and thrust washer wiIt1 clean ..... oil. then instal them ontolherelealerod.lnsIaIlhel!lleaselOdnto the bacl<.o! the pressu<e plate so lhat the headed end protrudes from the front lsee illustratlonl. 21 lnl t.llthepressureplateonlotheclulch Ileeiliultr.llonl.lnitalilhesprings.then install the prellure pla te bolts. and l ighten them evenly Wl. crtss·cross sequence to the specWied torqueMttlng l see lllustrations) 22 Apply a smea,of silicone sealant to the .re.around the cf.nkcasejoints as ahown lsee Illustration). Check thiol the doweia lII"e in place. thef1 place a new g8.sket onto the crricasa l_lIIustratlonl .lnslalithedutch C<JY.-withthereleualeverpushedback.and tighten the cover boIts.......ry in a criss-cross

18.21t .. .•ndUghtenthemtotn. specffied 10rq0e setting

18.22aApply.s.mearofse&l.ntlolhe areas lKTOWed

sequenca I.aa IIlu$lration s). M~ the release IeY.-forward sothiot lhecutoutin the shalt end engages with lhe release 1Od. II the

lower MId 01 the clutc h cable (.ee Nlultratlonj.Fulyslackentheuppernutand ttvaad the lower nut Off the end Of the adJUI18f. then slide the adjust8foown In the bracket to provide as much in.... tabla

:~t!~::*.!.°=rher~~~=;~~u~

clearane.between It and the clutch coyer. and again f!lO'Ie it forward 10 engage it. Make SUf e lhe pu lse gener8tOl" and oil pressure swilch wiring I$ton"ectly rOUled and secured by Its clamps l_ iIIul trBtlonS 18.3aand b). 23 COnn&et tl'le Clulch cable (see section t9, Step 3) 24 Refill tl'le qine wilh oil (see Chapter 1).

19 Clutch catwe removal and installation

~

'"

Engine, clutch and transmission 2- 35

f,"pfaya$poss i~ .. {.e. lllu 5tratjon).Fully sl&cken the Io<::kwheel on the Irooplay adjust8f at the handlebar end oflhecable,then screw Ihe ltdjusterlully in tsee iliustratlon). AJignlhe sIotSin theadjosl ... andlockw!>e&lwilhthatio theleverbfac ket. thenpul l theoutercabl. and ifom the socket In the adjust ... and relea ... th .. innercablalrom the le".e, t'u lI1u51.atlon . ). Now ,elaase tha low ... and

lJ
~~~~t~8~~':'~~k;!,:~. I~:v~~1 :::

Nol,, : The fl"Brchallg& mechanism e~le'naJ componenr p;orrs can be ",moved with I'"

clulcheover tseeillustrations) 2 RfIm<>v
&ngineirrthefranwJ

~

B a foreremo.lnglh a Cabie

_

from Ihabilca,lapaIhe/oWer a ndofllHl/Mwcable10 Ihe upparendoflhe oldcable. SJowlypullthelow.,...,d oflhe old

'IN

20 Gearchangemechanism (extemalparts)-removal,

inspeciion and inslallatioo

Removal 1 Remo.elhe engine (Iront) sproc k..t (see ChapterS) 2 RItITIOvelhesiOeslandswitch(Chapter8) AJso disconneclthe neuI,a l swilCh wiring conr>ectorlromthefl"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.

isC<:>rTeCt1y

~~: ~=::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 .... aodlo<::kwhaelwithlhalinthelever bracketand l~theca blein l otheadjosler t.ee

IlIus"ationsI 9.1_anddj.Thraadlheootson the Iower .djusla, to Ihat It i. secu'. In the

~E ~,::;~~~?v~~:;: gearchangeshalt lromthecrankcase ! II nec .. ,sary. remove the se,ew secu ' ing the pin i"o:)Ider p/ate to the 8fId of the .... ector

drum. Ihen ,emove the plate. noting which hoIelocateso.erthelongarpininlhes.ek!ctor

cableoul,guidinglhan_cM>Iadown ;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.permanenlthreadlo<::klngcompoondto ilslhreads, thenlighl&n~tolhelorquesetting specifier:latthebaginningoftheChapt....

2

2- 36 Engine, clutch and transmission

7 Chock the gearcharJge shaft lorstralghtness and damage to the splirle$. lithe shaft is bent you can attempt to straighten it, but il the splines are damaged the shalt must be replaced. Also check thecood ition 01 the shaft oil sui in the cover. II it is damaged. detenoratedorshowssigI1$OIIeal
SlJltable socke1. Similarly check the condition of the transmission output shaft oil seal (see Illustration) 8 Check the selector arm and stopper arm

10 11 removed,slide the centra lis ing spring onto the gearchange shaft and locate the spri"ll eods either side 01 the pin on the arm. Smear clean engine oil over the shaft then guide ~ Into place, lifting the selector arm and stOPP9r arm onto the pins as you do. and making Sure the centralis ing spring ends locate correctly on each side of the pinson the shaft armand the crankcase (SM illustration) 11 Apply a smear 01 silicone sea lant to the area where tile cover fits over the crankcase foints. Also apply high-temperature grease to the lips of the gearchanga shalt oil seal and the transmission output shafl oil seal in the

n&utral to be selected from lirst gear unless the output shaft Is rotati"llfoe the machine is moving). it is not possible to select each gear in tum 14 Instailthesidestandsw~ch(saeChapter8) ~~~~;~t the neutral switch wiring

12 If removed. instal l the gearchange mechanism cover dowels into the cran kcase Install the cover using a new gasket (see illustration). On 750 mode ls, apply a nonpefmanentthreadlockingcompoundtothe longer cover bo~sonly,andtightetl all boitsto the specilied lorquesettlng. 13 Temporarily install the gea rchange lever onto tile end 01 the shalt and check that the mechanism works correctly between neutral and lirst gear. Due to the positive neutral selector mechanism. which allows only

~;;::canberemov8dwithlheanginein

pawts.and t hepins i n th e~ectordrumfor ~ar and damage. Also check the arm return sprfng. and makesure~ is correctly Installed Replace any components that araworn or damaged

Installation 9 II removed,instal l the pins into the eod of the selector drum, making sure the Ionge.-pin Isfihad into the hole noted on removal. Install Ihe hOlder onto the pins. then apply a nonpermanent thread locking compound to the hokler screw and tighten it securely

15 Install tile sprocket (saeChapter 5)

Note:

The starter clutcil and idle gear

Removal 1 Removetheclutch(seeSectiont8) 2 Remove the oil pump (see Secbon 23) 3 Before the secondary shalt is removed, check the primary chain slack by measuring the amount of up and down movemf)fll in the chain mid-way between the cran kshaft and secondary shaft sprockets (see iIIustratJon) If it exceeds the service limit specified. the

Engine, clutch and transmission 2- 37

cn.in .....lbt~.RoIalelhecranksIWI

used. ~theKtrwasakiservicelOOl!l't-No.

and.-pul the~"'wriouslX*l1'

~1~~~~I:~:"::,=.=~~

=,~~~1~::::~~7 ..., r.pIaI;.

~

wilh . new one.

,otOf.urotenWthell8COl1daryohafloot.

I On750~,WOtkinOonlheright·1\aod

01 Ihe HCondary shall. 'emove Ihe ,emalnlng tcre .. l\lIeotllarasecured the 011 pump) IlICu,lng tha shalt bearino ,alai".,.

!o~~~~~~-::-;:::I:'=

~

Hroomltb .... oMObIe.lT'I8MyotJr OWl'lbe/of. ,emcwlnglhe..." ... ll1alttcan t>ecomoclly ellgnedwiththelhaflonlnstallation 5 Unaa_ 1M bOIls aecuring tM """II,ne

ptallandrllT>OVilthepialft lsee lMuslratlonl. II 7apIha!afl· handend 01 the ohan .... lh . I\anVner ""'~ the righi-hand end bearInO It

rool"'CIIll"lYIIIIgrvnenI~ !seelll"$tratlon)

~_ 1 0thecrnc.e"""""""

t h e _ (aMlIMtmiom! . I Remo.... lhe '''0 securing 1M aecondIryIhaflDeamgCIPand......,...!he CIP !seell... tr.tlonl.OBcarCIIheO-ring .... new one must be und. On 750 1'I'IOdeI5. 00 noIioHlhe...tringdImpL 7 To remo .... lhe .KOtIdary shefl nul it I, neceuary l0Iloplll&6nQine lromlo..orning. H

lei....

~ =~~':':'~;=' I~:~ ~::..~:

lIa,d .. ilh thfl ,ear tyrein lirmcontact .. tth the

oround .... lt... n. llv.ry. ..,nso::re.. ,he bollS

dlsplecedtromthecrankcase, IhenWllhdraw thetlvofltromlhlrlght.so.qxwti"'lllhlllart. cIutcI18r1C1<11mper-..blyw.1hIbOIIc:mol

::,::~:'~= :I~s:.i::::::",~ }~Ie==~:~:;'::'':a'':. 2

.J--, IntegratlkliOo.750modeIs 3Isoha...

"~

roIerbea'lngbetw88rlthe"""nlllld the,lart. drtven oear 1"o.Ib. which miOhl come OUI .... ,h the IIIIIIt but could Itayinside the start ...

. ~,.

~-- ~- . '

....

- ..-

HCIII1ng tllealtematOfcovw tothelel1·1\aod

21.ib .•• andwlthdrawll

$kIeot lhe engjneand remove lllecov ....

Iromtna~tf750modeIwtth

Oiscafd t.... Olaket .1. new one mus' be

""'*_burinOshown)

2- 38 Engine, clutch and transmission

21.10 _ _

E "~to

__

Md. _ _ _ cIu'IehasMl'l'lbly 2 1 .\k~_pr;rn.y_ IdkI~OHt'

.... tI

21.11 Seooondary .... fl and

ttatterclulchcomponeflU lSec:ctn<Mryshaft

~=Was/ler"

4P1-*n1rycMIIIP/lllf

5Citdp

6Thtuslw_

7Need/e,.,.....'-"'I1

""'-

'S_~goeer-

91d1e1.-.ct>ongeet'

,-

IOldlel.-.ct>ongtMlsMfl

:;!:bd/

"-.....

13 Srartef"durct> 16Spting

'7~/Iub

18Demperrubbers 19PrimarycMin

--

20BeatinrJsIIMMt 21 Sheflnul

"

23D1tr7¥*'ISaImOIy

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

ar<:I....."".M I_ III...tr.tIon). 10 Remo.e theE· cllpl.om ttleend of the

IdleiredUClkm 11''' .n.fI, lhen withdraw the , haltaodremo.. tllegear.ootlngwhlch way round~fi t' I_ IIIu" .. tlon)

Inspection II Insta" tl'>eltarler OrIvengNr into the

llart.. WlcI'If~~and,wttlttheclutcl'l facedown on a worltlMnch , cllecklhallhe gear rOlatN Ir. .lv In an anli'clockwi !Ht di...ctlonaodlock" galn5lIherotor ln a clockwise d irecllon (... lIIust',lIo n) , If II doe8n't,replace tttestarlerclutch 12 Remov. the ....edle blaring I.om the cenlre 01 the ,"rter drWen oea. II It didn't come out with the secondary shaft (750 models onIyj, Withdr .... the start.. 00-.

O'ar Ifom the tlart .. clutch. If It

'PPM'"'

IlUCl<,roweManti..::loc:kwiMasVOU wilfldraw It to I ... It I.om the IlIrt.. clutch, Not. the Ihr\lllw'sherfm..:fbe~lII8dn...,gear

an
13 Cneck the bearing sunaca of tile sla"er drlvotn oelrhuO and the condition ofth, roll .... In,lde the clutch bodV (,. . lIIull.etlon),lIthebearlngsurlac.tIIows aig"'OI.~c,", .. _ror llle rol""ar.

Engine, clutch and transmission 2- 39

damaged,marked or Ilaneoed at any point, they should be replaetd, ,.. Remove the rollers and check the plungEnandtprlngslorsignsofdefonnation or damage I_ illustration). Maka sure the pIuro(Ier$n1O¥8lr.e1y"IheirSOCkets 15 Check ttwlt 1fle three Allen bottssecuring

dlacovered on related gellf$. Alsocl\eck the idl....reduc:tiongear sllaft for damage, and check that the gear I,not a loose lit on the shalt. Repiace1fleshalt W.-y. 18 Enmlnethe secondary shaft bearings

1flestarleretutehtothedemperassemblyhub aretigllt I... mu straUon 2t.13). tt any are roo", unscrew .11 the bolts. then apply a witable non·permanent thread locking comp!ll
bearing will have be&n displaced with the seconclary ahalt and can be separated lrom the shaft by removing theeirc~p, primarydm.. gear ar'ld wMhet from thesllalt end: draw the bearing 011 the Shalt using a puller II ne<:esnry. Install the beari ng on the secondary ahalt u,ing a drilt or bearing drivet which bearaon thebearlng's Inner race only. The left-hand bearing can be driven out of the crankcase using a drift or bearing driver which bearI on its OIJIer race only. When installing the bearing make lI\I'eltlat it is positioned to the preclH depth in ita housing l lee IUustraUon): uae a drift or bearing driYet which beMi on the beamg's OIJIer race only

~~o;. d:':O~I~It~:~:~~~~a;:.~~::

andrepiacelhem!l~.Theright·hIInd

,-----------,

2

2- 40 Engine, clutch and transmission

Installation I' Lut>rlcate 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"51<..1 from \he lump 1t'od<:r.......... ""llngsorla.ces

In'pection 7 CII.n lhe sump. making sur.. alilhe oil

-.

~.="t:oIoiI"':t=·lsclean 'nd

•_ .... y debris c.UQhI In Ihe mash. Inapto;t the IIrainlt lor '"'1 signs 01 wear or

t Cltanlhflprauurar.lator.andchlc:k

lhal Ihlplungar movesfrHly in the body . In'ptCI It lor tlgnt 01 wear or dam"ll" and 'epIaca~ Wneceuary. '0 Remov,\he"veeollpassageO'OOgslltld th,oll filte
ones'oo'lttl1hellallidefacing lhecrankcase. _....-lhemwimCieanengineoll

In. f. lI.tlon tI HIMlOved.applyasmaRamounl o!lIOO· ,*"",*,lll"o'eadlocklngcompoondlO ' hloil Pf",ur'r'llula'orlllr.. ads andliglllenillo tl>etDrQUlHllingspee;liIdalthlblglnnirlg 01 thlCIlapt .. 1_ .....tratlQn 22.51. 12 l1yaMW\18sk,l onlolhesump{illhe ~.lnthllramejorontothlcranl
Ullhe 1tIglneha$ _ removed and;' poIitionadupeidldownootheworl<Sldacej . Make SUftllhe halls In IhI 91$1<11 align eonKtlywllh Lheboll holes. and that an O-mgI . . ln&talled 1_ ilustnotiol'>sl. 13 Po.ItIonthl-"Pontothla-.:ase_ Inslall IhlsumpDOlI ... TogtrtenlhlDOllta...enty ",.aIH·CfOM patt.n to tl>e torq .... selling ~lI*Iatt hebeginningotthllChapl ... l l ln.laJltl>eoitcooierhosesontoII>eIl<.<\'1P Vlln; new O·rln;, smeared with 011. and tlghtanthabolls lolh .. sp..d/iedtorq .... setting I.ee IllutlrlUon 22.3.). On 550modM.connect1heollpn!53Ul'elwitch

wirin(j 1_""'"tnotion22.3b).

IS ""taithee>
23 Oil pump - removal. inspection aoo installation

--.

Nota: 71woilpumpca'lt>e""""";..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 tw<) SCflWS I'"IlIu t t. atlon) . The scrawl.tso tecufl IhfI SlCondaf}' shalt bearing ,.talotr

pIa!t .AamoYethe DOll&'ldIhe~.noIincI how~

. . t taked tOthlretalnerpla\t.1t'od

_ 1 h I _ Irombeiow.OnSSO..-.

2

2· 42 Engine, clutch and transmiS!;

three

""""""theret,",ilW"p~t.wiItl tholscrews(on

750 models. the plate fs secured by

tfl""'5ctew& securing the po..mpoov .... then rernovethecov ... (.... UtuSlrallonl. Di5C1IrtI

=~~=~==:: :~:~~~:S~o:!~:e..~u~;~ ~~ thepo..n>p~lheyareloose

Withdnlwlhedrive""~ttllrod~srotorpin(_

Inspection

~:~::'\'!7'~~~:~~o:n~

" Inspect Ihe pump body lOt any obvioua damage SlJ(:h as cracks Ot distortion. and cIlecklhattheahaftrotateslreelyandwitholJl ""Ysidot-ta-oidIIplayOte_~ '

1'lrI
5 Whilst lhe pump can be dfsassernbled lot cleaning 100 inspection and individual components replaced II required, KIIw,",,,,,kl

I~ ( _ illulItnItionl. 8 Inspect the rotots lot scoring and wear. II at'O/damage.scorIngotun8Y9l'lote>
~=::~~=~~:~:c~~~~:!~:tt~ :::!=:~.rec~~~t~l s~a~~~~:: ~!'=::=P=~:;on;a:

:':~:d=~

IIluslnltIon).f'ushIhfl_ttll'ltough lhflpump unlil tfle drive pin is clear of the ~ gear. then remove the pin and alida tile driven gear

7 Meke sure the oil stralne, Is clean and remove any deM s cavght In Ihe mesh. Inspect the strai ...... lOt any ,;gnl01 W118(0t

011 ItIe shaft (s.. lIIustratlon). Remove the

"~ " """,:-._.oo .,,.... _~"_"_ """' ~-'-.~....,

any ,;de-Ia-side play or

23.1Qa L.oea!etltepvmp onto the tIowels

Installation 8 ~ removed. fit the dow,1s Into their holes in the crankcase. making s ur. they lire secu,e 1_lOustnotionl. 9 Before Installing the pump , prime II by poo.I
10 InstllU the pump, making sure 11 Is correclly located over the dowel. (••• Illustration) . On 550 moo:!els. in,lall the bearing retainer pIa!e (on 750 modeb ~ is SI~ 1 In situ. retained by a single.crew). Apply a su~lIble non-permanent thread locking compound 10 the threadl of Ihe retainer plate/pump 5Crews and bolt. then tighten themserurely (see Iftustra!lon 23.3). U,;nga cenl ra punct>. s!akethe 5Cre ws agalnst the ,etar.er plate 10 lock lhem (see Htustrlltlofl) 11 Insla~ the sump (see Sect..... 22) and the dutch (seeSec:tion 18).

23.1QbSl8ke tltescrewsaga;nsttheplate using a centre punch

Engine, crutch and transmission 2- 43

__ ""'''''''_(8) ® ® ® ® ® ® ® (j) (j) ® ~

24.3

u ppercra n kcaH haIr6mmbolts'~

Note: When

~

engiM is

upsi~

24.5 Lowercranke. .e heIf - 6 mm bolt, (AI. 8 mm bolla (B)

sach t>oIIls removed. stot& It In ils rslalilre

en{Ii",na.rlhe ends o/ the aankshaft as

Instal1edln rhecomlCt~\iorIon~.

shown. end one II Ihe back of thfl engine Notr. lff1lellalYadc>no/~I.....siIy.~ !I<1radlllslenersllaYllbeenremol'&d. Donor lr)'8i>dsepll<8""",l>8Nestly/everlrlgSQaf'ls! Ihecnmkcaumltitlgsur/ac8,18StIley.re

~ =se~.a~~.::=-:ae~;s::

24 Crankcaseseparatiooand reassemb/y

~

down

(S~4toI9}.l8femJIsto"",right.ndlett­ hMldend$or~otthel1a/l$mi$$k>nshslts

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}. sla<:kenlhet..,Smm_aa""".sebol\$e Iinle e tmeuntillheyeredfinOer·lighl. rhen reme"" the bolls. Note: ....., uch t>oI! Is removed.5toreltlnilSre/ati""p05it/onina ~ tampllteot thecmnkc~ ~IY&. , hiS will etI1!Iuno all bo/ts ano ItIsra/led in lhe correct Iocalion on raassembIy. 7 Cerelu"vtift lhelower crankcase hall off tI>e 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~_IheMle<:!O/ d......., and selec!or fot1<8.leavinglhecrankshaftrrdtransmissiorl shafts intl>euppercnnkcasel\all B Remove the two locating _ I s from the

crankcasaW t hey ltt"8_(tMycould~'"

etth... a ankcasehall).nolinglhelrlocallcns I_illustration). 9 Re'er 10 S«llons Z5 to 31 lor Ihe l"IImOVal end insla llation 01 the componenls tIouMd wilhin lhecranl
Reusembly Note: Kawasaki adviu Ihll/he 8 mm t>oIts shouJdbereplacadwitllTHtWOtlMifthey"""" tJiready bHnren>ol'lld rNe rimes before 10 Remove eillracesol sealant Irom the

crankcas8ma1ir1gSUflaces

gen....lorcO
~::~~-=rt:"=IS!.~~-:a:,:; idIeo'mductiongsar.oiIsumprrdoilpunprrual be~.Se
~

tl1lMmissiooc~tt.orloinsp#tCtthe CtIW>I<s/I!lI'I,.;thoot~It.the~top.

end COfI"/POIl&tlts (cam ch8in tensJoner. csmshsfts,cylinder llftlJd.cylindertJkx:ll, p/sIon$)cenl'8m9lnln$lIV. _ _.if~

01

rhe ctankshllfF and

COt>t>«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 Checl
15 .C!*'kegaln thaI en compooenll ",e "" poIOtion.plr1K; ... lartythltthtt~lringllleu'S .., Itill correctly located in Ih' lowe, cr..,kCollSllhall.C".'lIIfylnstallthe_... CtIlOkcaM hall do..., onlO the uppet c,anl
.-owaonrv,*,I•• IIO~H/el:Tedlrom,",

oear ......... Ihe.DU1pt11lhaflitfOtatOng(le1he m&chinelln'lOWlgl,~lInotpoulbtetoMlect -.::hoearlnt~..-.:Idlecklhethafts. 18 C1eanIhe~oIthel",emmll>ww

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<:escln be cleaned up wiIh.fIne~stoneorgrindsl_. 8.~..,. e.,..flll nollo nleot or gOllgetl'leet"llllotc... m e l/rlgsllrt_ .. or

C.... ,Ion:

Engine, clutch and transmission 2-45

0_

oIIlN11.dfftUlt. Chlc:kbolh cranllcne hiNH ...". CMIfully f« cndI. _

........

. $mIOII
..

=e!:~' ~:rired.

'eplace Itli

5 Oamroged th ...ds c.n b8 KOnomlcnl1y ' 8Clalmed by using a d iamond seoction ... l.e Inaer1. 01 Ihe Hetlco< l ty!)e . ... hk:h I. easily ~~ft.drIlW1vand""I.oppIngIh&alf8cted

2 a.lrtngllllu"oc:~,,",mainlybecfouseof l.ckof lubCI of dlr1 or otn.'tor.ignj)ll1ic:lel.O¥ertoadingltMoengine

--

hMtIt producIdtodriveofflhlc:ondenlld wll.. lfld~ga!I8!IproducId.TheM proob:bcollactlnlhlengineol.lom*IglICid

a"IdIorCOlT'ON:ln.~~Ihec...~

and~l4lhf101lscamed t olhflanglnl

bMr1ng ...... MmustbllcorreciodbeloreltMo

bMringt.theacldlttacks andcorn:JdMthe beaTogmalerlai. 1 lncoomctbeltinginslallation leadtolaikq. a To avoid bearIog problema. clolan'"partl thoroughty belorefl...,,,,,,bIy.doobIIche<;I< III Delfing d .... ne .. """.u"'"""" and Iubricatllh&""",bear'ngs wilhclMn anginl oI
.ngIne"' _ _ ~IOpnt\lllfllitlrom :I WIlen l>IImlnlng 1M COMICIing rod bMrtngoI • • ltmOYllr..ntromtIHtconnectJng rod'Ind~lndllylllemoolon l ~"'n

.....rt_ln lhe ...... gener.. positlon .. their toc.tlonon the~'riahaftjournals. Thi . ...m anabll yoo 10 malch Iny noted bearing pding c •• nkltlall

,..,..

4 D01a"1dOl,*tor.Ignparticlesgetintolhe

.ngIne In a yllflely of ...rqs. II may be 101ft In lheengl.,. dl,ll"\ng ........ blyor II maypess ttvough~ ... orbrlatllerl..ltmay08lIntoItMo oil Ind I.om 1'*1 Inlo the bearing •. Melli d"OpItrom~operetionsandnotmai

'--------------' II Stleared . , ud. or IC .....S

~.n

usu.'1y be

.emoved"';Ih ICtflW ..".clors.whichconslsl

of a taperld.left-th.eadsc.e ... ofveryha rd ....... TheM .... Insert..:l Into.pr&-dlilllld hoII In ltllIlOO.and\IIUallylUCClfldlnd4s1odg1ng lhflmost lIubb01"nliudor""' ..... ~aproblem _ _ which_bIyondYOOOscop\l.HII; WO
Many of these firml ao:!ve
~lnlh&motorc,dapr-.

a-II\II II IhfIcyindllrh6adsludslll IightInIh&CtInIIcIMhalvaH~ ... IooM. .-Ihem.noting wI'lic:hIits-..""\he')' ... 01 ditt....,1 '-"Otht. then clean the/l' Ilveadl.Apptylsuitabienon-pfIm\at'IfI!ll IIv.adloc:kingcompoond.ndtighlenlhlm 1

-....

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 1<""" avMy1ning lpol"""'Y""'andurtngengintl ...ssembIy . ~oiIa"ldMerc:t\anoel ...

5 l8dt of Iub
O¥ertoading(Wl'lich-.-zes lheoilfromltMo belrlngllCe)lndollllakagoeorlhro... ott (trom ..~...,... bMr1ng cIeIrIInces • .....,.., 011 ~orhlghenglnespeeclsj"contribollto

lubrk:etlon brukdown. Blocked oil pessegIS "' 11 , ~, , _.bea+.gm destroyit.wn.n

8 H'_..:I.lnslllllhfljetsinI0IheireotrflCl Ioc:aIklnslndllake lhejetadjacenl lolhfl bigend ~"nglnplac. ,takingca ... not to d"orm ltllnoule (.Hllluttrlllon25.1.j Alsolns"UtherubbaroilPi'ssageplvglnlo lhe l.anl",I,1Ion Inpul shaft righl-lland

liCk 01 'ubrt~ ..,on I, Ih .. causa 01 bearing 1,l lv... thl bearing mall.lal II ""ped or , w ooed I,om Ihe 11&&1 backing ol lhe bel.lng.Temper.. u••• mey ine..... ,olhe

DUrtngcut-outinlhl_CfWlkcasetlllll~

lumba.-Irom~ting

poIntwlterelh&sl .... bIocking_lh&joum..

lWTIO\Ied (_IMv.tratlonl25.1bj.1nataII1I 0Iher componanI. and -ooIIes. referring tolh& ............ SectionI~tt.-O\apIerlfldto :::::.- I. bItcft.-nbling Ih& CtInIIcIM

1 Even though main Ind connecling.od bearir'I(II .... ~ IIy.epIaced ... iIh""""' OfIII

:=': ~~:':~':a~ln'::':

theymay' ..... a1y.,uabilinfom\aHon.bout tt.condiIlon~lhIengine.

1 RIdIng 1IabIt. can 1'Ia.... definite eff-=t on bMr1ng1ife.FoAItfo!IIoIlowspeedoperslion. orlabourlng lheaoglne. potlvery l'Oghloacb onbeerings.whichllOdtolQ\lMZ.OU1lhf1oi1 mm. These Ioadl cause 11'11 bearing. 10 !\ex. ... hlch p
from IhfI "eel bIckIng. Short lrip riding IMdi locorroalonOlbMr'ngl,asOrlstJf!icilntanginl

--

N ot.: TO_/he~ftl"'engine

"",.,N.-mowtdfrom /he frame and l1'li

1 Separat. t hlc:rankcasehalves(Sflc1ion2~) . 2 6e!oreremovng thecrankshaft checklhe

:- ~':'::it ~ a':-lha~ t;";': beItIng)aumal_~ IhIdNnn::e(_

. . .tretIon) .~",,~wiIh tt.-ChIIptKISpec/I'icItionstllhfldlolnnce :~. ~ lhacrriclutw- .. :I un l1'li crankshaft tDQ8lhflr with l1'li OOfWIIKltIngrodl,camchalna"ldpM\arychain

00104 the upper Cl"lIlkcaH NoH , _ ....tretIon).WlhlcrwNI'Iaft _ _ "ucI<. I., H genlly using • soft-faced m.,Iet. RenIove lhe 011 seal from each Ind oflhe c .. nkshaft .nd discard lhem as ...... one.

M'

2- 46 Engine, clutch and transmission

27.108 Crankshaft main bearing joumaland c rankplnjournal 4 Thto main bearing shallscan be ramovad IromlheirevtOUlsbypushingtheircentrasto ~:~~~:~ tham out. Keap the

lju

marlr.ingl

O MairlbåjoomaJdiametfJrm8ll<-,marlIorUllm911<8d Ctaro!
o

, -_ _ __

_ __ _ _ _ _ _ _ _ _- - ,

5If requir&d. r"",ove lhacon""'t ing rods from Iha crankshaft (sea Saction 28). and diser'lgaga tha Cam chain and primary chain from tr.e;roprockets.

Inspection 6 Clean tha crankshaft witn soIveot. using a r~le- cieaning brush to scrub out Ih' oil passages. If available. blow lha crank dry with oompressoe<:I tW. and also blow tlYough thaoil pa»ageS. Checkthecamehainspt"ocketand pr'onarychainaprockatlco"wearordamage.n any 01 the Sj>rockel lealh are ucesslvely worn. chipped or broken, the crenkshalt must bereplac«j.Similartychecktheprimarydrive

~:;t;,a;:!!'~==:a:::.. ma.. bearings. If IMy ate scorad. bad~!lCUfled or appear 10 ha .... bean seizad. new bearings must be Installad. AJway1r replace the main bear'ogsuasel.Hlheywe badlyd"""'98d. checklheco
DiI hollis and pass.ages belore"*'S$"",bling

lheeng;ne 8 The c,an~shaft journals s hould be gi""" a close visual examinat ion. payingparl ic ular anentoo_edamagedbeanngsha .. ,been discoverred.nlhejournals .... scoradorpit1ad

on tlla outsida of the crankshalt webs (see lIIustnttion) . The cOO'espondir>g main bearing housing",z"rnat1<s(eOtheraOornomar1<)are slampedintOlllafrontoftheuppeo-crankcase half (see illustration) l1 A.rangeolbearir>g_lsls avaJlable. To select Ihecorreclbearir>g lor a par1k:utar iOUmai. usirrg the latNe below cross-relar lhe mainbåjournalsizemar1«stampedoolha crankweb)withlhemainbewing~size

in anywayanewcf3l1~shaftwi41barequired

mark (stamped on tile aankcasa) IOdetarmine the colour code 01 the beanr>g r&q~lrad . For example. II the iOUmal s ize Is 1. ar>d tlla housing s l:e Is unmarked. tllan the bearlng reqo..OredlsBlack.TheCOlr:u"ismar1<edon!he

Note that und ... sizes

sidoeoftlleohel tseeillustratlon).

afe

nol available .

~=glheoPt ionOfra-grindlngtha

gPlaca Ihe cranhhalt on V·bklcks and checklherurlOUlBttllamainl>earingjoumals uSing a dial gauge. Compare lhe read ir>g 10

:~ut~a=!:~:"'~t:,:'~~~;:e!~:

~~uretheshensar>dcrankshaftareCIean

Chapt er.lltherur"lOUlUceadstllalim~.tha

Main bearing shell selection 10 Aeplacement bearir>g shells for lila main a selected lit basis Marks stamped on various component. are used 10 identify Ihe corr""t r<)placement

beamgs.Thecrankshaftmaint>earingjoumal

s ize mar1<S (eOlher a 1 oroomar1<)ar"s~amped

14 Pres. lhe bearin,. shells Into their cuI· OUIS. ensurlr>g that the tab on each.heH engages In tlla notch In thecranl
l hemaximumspec~>eda t thebeginningolilla

cranksha!tmuslbareplaced.

bearing$ are supplied on

Z1.118earingshelloolourcodeloc:atlon 13 Clean !he back$ 01 !he bearing s/>eIlsand ; : : a ring hou'ir>gs 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 finge<-tight. then ,emove the bolts. Carefully litt off the Iowe.-crankcase hall. mak ing sure the Plasligauge is not disturbed 19 Compare the width 01 the crushed Plastigauge on each crankshatt joumal to the scale printed on the Plastigaugeenvetope to obtain the main bearing oil clea,ance (see illu stration). Compare the reading to the specifications at the beg inning of the Chapter 20 If the oil clea'ancefalls into the specified

' ange. no bearing shell replacement is

;:u~~a!'~~ ~:ea~~nn ~ ::::~r~ :~~ ~nl :h~hi~;:: =:m~~;:~ero~ :~: crankshaft aOO setectnew bealing shetls (see Steps 10 and 11). Install the new shells and check the oil clearance once again (the new shells may bring bearing clearance within the specified range). Always replace all of the shells at the same lime 21 On completion carefully scrape away all traces of the Plastigaugematerial from the crankshaft journa l and bearing shells; use a ~'!:~~ other object which is unl ikely to 22 If theC!earance is greater than the service limit listed in this Chapter's Spec ifica ti ons (evenwithre~acemenlshells),measu re lhe

diameter of t he crankshaf,t journals with a mic 'ometer and compare your findings w ith this Chapler's Sper;ificatloos. By measuring thediamaterata numbero! points around eachjoumal·s circumference, yOU·1I be able to detarmlne whether or not thejoumal isout-ofround. Also take a measurement at each !l
Installation

Plastigauge (be Sure touse the corrlM:t scale-metricaOOlmpenaf arelncfud&d)

23 II removed. install theconn&e ti ng rods onto the crankshaft (sooS&etion 28). and engage the camchaln and primary chain onto the
25 lubricate each shell. preferably with molybdenum paste. or i f nota~a i lablethen wittlcleanengineoil, Press thebearingshetls intotheirlocations, Makesurethetaboneach shetlengages in the notch in the casing jS<'le lfIustration 27.14). Make sure the bearings are fitted in the correct locations and take care not to touch any shell"s bearing surface with your fingers 26 Apply hig h temperatufe grease to the inner ilp aOO sHicone sealant 10 the outer lip o! each crankshaft oil seal. Fit the seals so that the arrow marked on one side faces out and points in the normal direction of rotation of the cran kshaft (with the engine the correct way up. the right-hand end of the crankshaft rotatesckx:kwise as you look at it. and the teft·hand end anti-clockwise). 27 lower the c'ankshaft into position in the upper crankcase. leeding the cam chain down t hrough~stun~ (_ iIIustrallon27.3)

28 Reassemble Ihe crankcase halves (see 5ection24).

28 Connecting rods - removal, inspection and installation

~

~

Note: To ramova Ihe connacting ,ods lhe engine musr be removed from fhe frame and IIIe crankcases separareri.

Removal 1 Remove the crankshaft (see Section 27) 2 ~fore removing the 'ods from the crankshaft, measure the side clearance on eachrodwithafee~gauge (seeiUustration)

If the clearance on any rod is greater than the service limit listed in this Chapter"s Specifications, replace the rod and recheck ::;:,,:~,:.!:.iS still too great. replace the 3 Using paint or afetl marl<er pen. marl< the retevant cyl inder identity on each conn&cting

2

2- 48 Engine, clutch and transmission

, od and bea'ing. Mali< acmss the cap-toCOMeCting rod lOIn and nole which side 01 the rod faces !he/rorll of the eogineto en ...... e that the cap and ,od a re filted the cOrfect way aly . Note thai the leUef 8Iready across the ,od and cap indicat"" rod wetght -eachleft-tlandor OgIlt-handpal, ol ,ods should hIIvathe ""me lettef for prope' baIa.nce IMelllus".IIon28.8) 4 Unscrew lhebog-end cap nulS8ndsep8.-ate

the connectingrod,capendbolht>earlng shells ffomltleasnkpin (...... illuslnttion). Do

nol remove Ihe boilS !,om Ihe coonecting ,oris. Keeplhe,od.CBP. nulsand(rtthey8t'9 1o be ,eused) the bearing shelis logelh&rin ~~II=ectpoSltlonSloensu,ecor,ect

6 If not already dooe (see Section 16). apply clean""ljineoillothepistDtlpin.insertil inlo the conr">9Cllng 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 waeanng for 8 particular bigend , us ing lhelable belowcross-rsf", lhe Crankpinjournal s ize mark (Slamped on the web) wilh Ihe connecting rod size mark (siampedon tM rodj to determine lhecolou" code of the bearing feqvifIKI. Forexample,W the comecling rod size Is O. and lhe crankpln is unmali<ed.lhanlhebeafing required is Bfue.Thecoiourlsmarkedonthe5ideof lhe shell (1M iIIuslr.IIon27.11)

Engine,

Oil clear ance check

::lii:::,ays ,&pf_afl rn the Inserts at the

10 Whetl'>er new bearing shells are being fitted Of the ortginal ooes a, e being re-used, the connecting rod bearing oil clea ,aoce should be checked pfiorto reassembly, II Clean thebacksrnthebearing"",,"lsand the bearing locations in both the connecling rod end cap 12 Prfls t he bea,ing SheUs into t heir locatOons,ensuring that the tab on aach """"I engages the nctch in the conMCting rodIcap tsee IPustnotlon), Make sure thebearings ...e filled In theCQrrect locations and take care f\OI to touch any $h&II's bå w rr_wlth

yourllnger5. 13 Cut a langlh 01 t he apprOflrial e size Plltst~(ft!!houldbe5lightIy5\lor1"'than

th,widthofth,crankplnl t••• lIIustration 27.16). Place a strand rnpjutlgaugeon the (cleaned) crankpin journal andfil Ihe(cHlan) connecliflgrod . """"Is and cap. Make sure lhe cap is f illed the corn,ct way around so the pr.".,;o....slymade marll!ctingrod!loes not,otate.$tackeonthecapnutsandrerr>0v9

:t:~~;:~I:~a~~

taking great care

" Compare the width 01 the crushed Plastlgauge on the crankpin to the scele

-..

prlntedonlhePlasligauge~toobtain

lhe connecting rod bearing oIi clearance t_ ;Uu stration 21,19). Compare the reading to the specilicatkms at the beginning 01 Ihe IS llthedear......,.,Is";thinlherangellst&din lhIs Chapter's SpecifICations and the bearings are in perfect condition. they can be reused. ~ the clearaflCe is beyond the service limi1rep/acfllhebeariogshellswitllnewooes( ..... St"P58and9).Checktheolidea,er>ee0l'l« again (the new sl*lsmay be thick enough to b
16 If the clearance is Still greater tl\an t he s&rv>ce 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 <\(lIermine wnether or not the joumal Is out-Qfround. Afsotake a measurement at each end of the joumal . near the crook throws, a. wefl as in the mkldHl.todet¥mlneif thejooJ<'najis tapered. 17 If anYlournalhaswo,ndown past the ser:vlcelirnit. replacetheCfankshaft. 16 Aepeatthe bearing ""IIIctionprocedur. fOf the remaining connecting rods '9 On completion carefully sc ,ape away ali trac&!I of the Plastlgauge malerial from the

crankpinandbearingslloOlsusinga lingemail :;~herobjectwhichls""likefy toSCOfe the

c lu t ch

and tran smission 2. 49

roughnessortigh"-s"emovetherodsand re-check thebeariflg clearance. Someti mes tapping the tlotlomrnthecOfVl&Cling ' odcap

:~=~t08S$. but ~ in doubt. ,echeck 23 Install the crankshaft (see Section 27)

29 Tra ns m i$$ionahafts removal a rrd installation NO " : To~vefMtf~shaflS fM ~mvslber&rr>OlledlromtflfJframelNld

foe cnm/(CllSoIISsapamfed. Note: fIflferrnlsrolherigllllNldletr-handenm of lhermnsmissionshatr, ,,",,, lI>I>dfJastho<Jglr the enginfI is the correcl way UP. ever> tl>ougII

-.

throtJghou t thisprocedlJ«Iirl$lIps;~down. ",eretorethe~l!t - handendolasharrwiH

acrvellybeonyovrleflasyoulookdownonfo

lhe undenJide o( toe upper

cran~ca ...

Removal

Instal/ation 20 Instafl the bearing shells in the connecting rods and caps, aligning the notch in the bearing wah tI>e groove in the rod or cap (_ illu stration 28.12). Lubricate the sh~ I ", pref",ably wlth molybdenum paste. or ~not avaitablewittlcleanengioeoli.andassemble each connlOC"ng rod on its corrftCl crMkpin so that the pr9YiousIy made matcllmar1<s afign and the ,ods lace the right way (see Illustratlon28.4). Tlghten the "",ts flr>ger_tight at this stage. ChlOCk to make Sure that all compon-ents have been returned to their Orlglnal locatkms using the marks made on d<sassembly. 21 Toghten thebearlngcapnlll,lothe tOfQU
I 5epaei,,~a tive posltion"

,n the crankca"" and how they fit togetl\er (_ illustration). If they are stuck. use a soft-

29.2U1t theshalts outollhecrankc... t550 six-speed t nlnsmission shown)

2

2- 50 Engine, clutch and transmission

laced hammer and gently tap 00 Ihfi aods 01 theshaftstolrHlhem,

3 Remove Ihe caoeo-ball bearing hall-ring retainerlalld lhelllMldlebllaringdoweipons Irom the upper crankCIISllh.aIf. noting how

check that the 1$1 gear pinion on Ihe right-hand endoltheshaltrotat8lltreelywittlout snydrag (rem<)VII the input sNlft beloramaking this check). Ifdragisl9lt.removelheneedlebeMng outerraoefromlhe~-handllt'ldoftheshaft.

IhIIy mIHfllllustrationt2ll.Sa;ondb).1f1hlly 8fencMin lhllirsioIIOfhole$lIltheaankcasll.

1hIIn.......,...Itlecin;:lipandneedlebeMngand

rernovethemlromlhebllaringsthemsllives 00 the sNlfts. 4 11l111Celury. thelnputshallandoulpul

one. The standard washer is I mm thiel<. ReplacernentlareavailablellithllrO.1mmor

shaft can bedisasMmbledand inspecled lor wear or damage 1_ sec:tion 30)

Installati on 5 Install Ihe caged bell bilaring hall ·ring ratalnerllnlO Ihelr Ilots In the upper

ruplacelheplainwashefbetind~.,..;tha1timer

O.5....."tNck. 7 Lowei' the i"put shaft irlto pos;tion In the upper aankc8H. making sure thll hole In thll needle bearing &ngages corrttetly with the dowel. and the groove in thllcaged-baO bea'Ing &I1gag&s correctly with the bearing half-ring

crankcasehaH. a ndinltafllhelllMldlllbealing

dowelslnlothelrholel lHflIUustrations)

ratal ner (MIl lIIus tretlon) . On 750 modell. check thai the sNlftroIatesfreelywitnoutany drag. If drag isl9lt. removether1e8dltlbeaMg

6 Lower the output shsft intopo$ition in the crankcasehaH. making .... e the hole In the

out. race Irom the 1IIft-hand end of Ihe shaft, 1hW\.......,...Ihecin;:lipandroeedlebeaMgand

IlIMIdlebearing~COffeCllywithlhe dowelandlheQl'1)CNtlnlhecaoed-bal~

replacelhewasherbetind~with a It1innerClllll.

The

Standard waaker

is

1 mm

thick.

6 Mak , sure bQth transmission ShaH. ara COfTectlysealed and their related pinions are COfTlIC1lyengaglld. C.wliDn:" lhe caged-ball bearirlg half-ring ,.,air!ers M nlNdlebNrirlgdowalpln••,. no l CQi't'fi:11y engaged. the ",.n*"as. halvet will not seat comoctly. 8 Posilion the gears In the IlIIUtral posiTion and check the shal1s are Iree to roIate easily IIIldlndependently(ielhllinplllshaftcantum whltstThe output shalT il held staTionary) be!or.procalldlngfurthar 10 R.assembly the crankcase halves (see Seclion24)

NOTe: RefemIs to fheright andlllfl-hend ends oIfhettansnQs,onshtJflsM8lnKfeatt>ough

angages correctly with IhII bearing hall-ling

Rep!acement._availableeithllrO.1mmor

theyM8in$ta/ll!tdinlheenginelllldlhe~

retainer (... Illust,aUon). On 150 models.

O.5rn'T11tick.

Is tllllc:orrect way up.

Engine, clutch and transmission 2- 51

3O. 2SiJc -~tno nsmi ssion .

inpuishaftcomponentS IN
~~~ 52t>dgearpinion 6Cirdip 7Sp1i1>9dw8Shar 86fhgearpinion 96t11gearpinionbusll IOSplinedwllS/Hl( II Cirdip 123rd14lhgear pinion

13 Cirdip 14 Sp1ined ............ 1551h geerpinion busll(B4. B5andB6m0d8/sonJy) 165thg
17/npu1sh11f1witllinlsgra/ ISIfl/NNpinion 18CagtKibBJIboatillg

1 Remove the lransmiss
8 Check tile gear t....th lor cracking chipping. pilling and other obviOUS w.ar or damag.

disassembko!helr.lnsmissionshallsseparat8l)t to avoidrnixingup!hecomporlllnlS.

Arrypinion lhat Is damaged as such muslbe

ZR550 mtHMl. -

9 Inspect the dogs and the dog hoiesin the gearslorctack • . chips,and.x~slvewear especI8l1y In lheform 01 rounded edges. Make svr.mallnggear1lengag.""operty.Repiace

six-speed trBnsmission

Input shaftdisassambly

-.e.

r;:=~Ig:~f~~onthe pinions, bushes and shaft. This could be

f:~r~~i ~~. ~'ha::~~~~ a~Ut~~::n,:::uaa~ =~: :;,'!ear. 2 Removetheneedlebeafingoute. r_ lrom lhe leh-hand end 01 the s hah. then re mo.e tha circlipand Slide tha naedta baan"lland thickthrustw8~andthe2ndge8rplnlon

olfthellhaltlMe llluatnotion). 3 Removathac irclipaecurif'lglhe6thgear pinion.thenslidethespiined wMher.the 61h ~:';.!i::'t.:':.a~S t)o$h. and th.spllne(! 4 Removelheclrclipsecurlng the combined

~::It~rpinion.lhenslidethtlplnionOff 5 Remo.athecircl ipsecurl"ll,he5thg.ar pnon. then slide the spHned washer and 5th g.ear p;n;on off the shaft. along w~h its bush (B4.B5andB6mode1sonly) ~r:;ehtgaarplnionlslntegralwiththe

Input ahaft Insp&ctlon 7 Was h all 01 the components in clean so/ventandllry\hernoff.

"-

onto th8 shaft. and check it lor play touglvless.

0<

Replacelhebear'ngil~iswomor

I"

ChecI< lhtl washers and replace any thBt are bent or appear wea k_d 0< wo
Input ahaft reassembly

15 Durtng reassembfy. BPp~ molybd.num past. or enoine 011 10 lhe mating sur1aces 01

::..:a!'thP;;::!,

~~ ~~s.::~\~St~' t!:

R.place any damaged

~o:":xs;.an~ -:'1IO~~ta~~7 :~h:rc~I~~ dl~

l' Checklhat each pinion moves Ir""fy on

nec.ssary. and Install Ihem so Ihal Iha

~:ka~h:= :S~='~I;r~t~ ~~~~:a~~n:£:~~:;: ~n':~t~~::r~tain damage the Ref... ~ of TooI!lend Wot1<shop Tops in

=~~~n:;l~a~~~z:,:~~~=,a; ~-_"_"._.~-~~=~~

the machine has oovered a ve
Replac. the baarlng I1l1la wo
damaged, using a bearing puller to remove

~

(MelliustraUonl. II """is oot a'l3ilable. you could

tryca",fulyl."'ering~offusingapairof

~fI~Ka:kl~d:a\:.';::::I= 'c:-::-c--''''-''''''--,-~ usingaprau.lns\allthtlneedler<>lerb8ar\ng

2

2- 52 Engine, clutch and transmission

16 SlideIhe5thgearpnonanditsbush(84, B5andB6rnode1tonlyj,with~sdogsf~

fNlayfromlhelnlegral lsI gear. 0010 Ihe 1etI· handendollheshafl (see illustration).SIide lhesplinedwasheronlolheshafl.thenlnstal lhedrclip. maklngsurelhal ~ Iocalescareclly in Ihe groove in lheshafl lsee Illustrations) . 17 Slide Ihe eomb ined 3rd/41h gear pinion onlo thesllafl,$O lhal lhesmaHer(3rdgear) p inion faCEIS the 51h gear pinion dogs (SH ill u$ tratlon) .secure~"'pI_wi lhlhe eirelip,

proper;yseated in ~sg rQOVtl lseeillustratlon) 18 Slide the spline
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.

Engine, clutch and transmission 2- 53

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&<::lIJSsary 10 displace the sleel bails for IhfJ

23 Remove lheeirelipsecuril'lg Ihe3rd gear plnion,the<1s1;d<1&spllnedwashar,lh&3rd gearpinlon,lhe4Ihgaar pinion.the3rda<1d 4th gear pinion bush and the spllned washer off the shaft.

24 Remove the circlipsecurlng the 6th gear

pinlon,lhenslldelhep/monolftheshatt. 25 Remove the circNp securing the 2nd gear pinioo.the<1stidethespi;nedwasherandthe 2nd ge3r pinion oIf th8 shalt. Output shaft inspection 26 RelertoSteps7to14above Output shaft reassembly

pos~lveneutralsY5temfromlhes'ots;nthe

shaft and into Ihe holes in the pinion using centrifugal force. S<Jpport the shafl verHcally wilhlhe5thgearpinionfacingdownandhold it above a SOfteoniaine. padded with rags Intowhichillepinionandbaliscandropwhen lhsshaft is rotsted. Holding the shalt by any 01 the freely rotating pinions, $pin lheshafl 8$ hardaspossiblewhilekeepiogitasverticaias possible (see illustrlltlon). WhenlhebaliSartl flungoutoltheirslotsandintotheholesinlhe p;nlon, the pinion should drop oH the shalt Takecarenotlok>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 eerS see1ioool Tools and WorksIXJp Tips in the Reference section of thi$ma ...... a ~.

2

2- 54 Engine, cl utch and transmission

28 Slide II>e 20d goear piruooonlo lheshalt. followed by II>e epm.d wa1het. ard secure lh@rninplmoewrtht"-Qrdip,meI
28 Slide It.. Sthgtar pinoon onlo the shaft wrthitsselectorlorlcgroowofaciogawaylrom

1tIe2ndggrplniotl.andHCtJ.eitinplaee wiltl II>e cirellp. making ..... ~ is property seated lnits~ i_""'tr~l

30 Slide tl>etplinewa1het. followed bylhe 4"'and3rdgearbo.lVoingonlolheshah.!hen slide lhe 4th !I"' pinion and Ihe3rd 11"3' pillion onto the bI"hing, followed by the solillll walM<, and lMCuri ttlem with the c ~cl ip,rnaKlllg ..... a~llproperly_ tedlni!S

groo.e ._'llustratlonl l

~ w:':h5:::r=~:'

=.:;:

sysfernball."'foaachof ll>eholes 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 notWDll<.Ho!ding lhaahafl.....nIcalardthepiniollnat, _1tIe

Do

Engine, clutch and transmission 2- 55

3O.32d ... • ndHCur. tnem

whh .... clrctlp .. pinion onto the.hatt with the selectortork grocMIJdrlglhe3r
:':=.!c~::-=~he~~

1he1hBlt,1hIreby~lhepinion.by~

tosblhepinionotrlhellNflllQllin 32 S11dethe,.tgearponionontottleshlh. l~bythethif;lc1hnlstw

_ _ 1he

~bMr'ng I_Htu.tnotionsl .s.c....1he

bMr'ng W'iIh IheQrdlp,........-.g ...... ~Ioca t ... correctly in the lI'oo~., then fit the bearing out"',_ I_HIUltratiotlsj 33 Check that all compon .... t' ha •• been corr«:tl)' .... tlliled.

ZR750 • flve· speed transmission Inputlhaftdita.sembly

~ • I

Wlt.ndJuIS""blin"t,..

rn n.ml..iofl,hIIhs,pr_ rIMparh on a Io<>grodor

r _ . wiN rlmwgh rlMm

rO~HPr"""inorrl.r . ndfltCingrIM J'f'OIMf" __ t/on.

:mR~:-::It~~:!~ ~~ s':~; ;= remove the clJ'¢lIp and sHoe the n~" bNrIng . plalowuller. the2ndgearpinion, the ~th gear plnlon.nd its busll. and th. It.-ust Wu/lerof!lhet/latt l _ illustnotion). 35 ~theo;ll'l;lip"""uringthe3r
pinion,thlnllldtlhepinionoftthestlalt.

-.

311 Rarno .... thecircHpsecomgthe4thgear pinion. theroailOathe1hnlst washet' end the pinionotrthlshllt. 37 ThllltQl.rpinlonislotegralwith ....

Inpullhattlnapeclion 38 Wa'" aU of the components in c!Nn IOtYe
2- 56 Engine, clutch and transm ission

damage. My pinIOn that is damaged as such must be replaced. 40 Inspect the dogs and the dog holes in lhe gears for cracks. chips. and excessiw wear especially in lhe iormoi roundededg(lS. Make suremaling gears engage properiy. Raplace lhepairedgearsasasetiir.ec:essary. 41 Checkiorsignsaiscoringor~uingonlhe pinions. bush and shaft. Thisoould be caused by ovemealing due to inadequate h.lblicalion Check that all the oil holes and passages ara :~.RaPlaCeanYdama9adPinionsorthe

42 Check Ihal each pinion moves freely on the shaft or bush but wilho\.Jt unduelreeplay. Check that tllabush moves freely on the shaft but without undue Ireeplay. 43 The shafl is unl ikely 10 sustain damage unless Iheengine has seized. ptacing an unusually high loading on the transmission. or the machine has covered a vary high m,leage Check the surface 01 the shaft. especially where a pinion turns on il. and replace the shaft if ~ has scored or picked up. or il theo"e are any cracks. Place the shalt on V-blocks and check therunout al the shaft centre using a dial gauge. Damage 01 any kind can only be cured by replacement 44 Check the caged-ball bearing ior ptay or rooghoess.andthalil isatightlit on theshaft Replaca tha bearing if it is worn, loose Or damaged. using a bearing pu ller to remove il (see illus tralion 30.13). II one is not available. you could Iry carelully levering il oil using a pai. of ty.e levers, though il is preferable 10 takelheshaftloaKawasakidealer. lnstalithe

baarir.g using a press. Install the needle roller bearing onlO the shaft. and check it lor piay or rooghness.Repiacethebearingilitiswomor damaged. 4S Check the washers and raplaceany that arebentorappea._akenedorwom.Q;scard all the cirelips as new ones must be used Inputshaftreassembty 46 Ourlng reassembly. apply molybdanum pasle ore
47 Slide the 4th gear pinion. with its dogs facing awayl.omlheinlegral1stgea •. onto the left-hand end of the shaft. fotlQwed by Ihe thrust washer (see iIIuslration s). Install the Ci.clip. making sure that II locates correclly in the groove in the shaft (see illustration) 48 Slidelhe 3.d gear pinion on to the shaft with ~s selector fork groove facing away from lhe 41h gear pinion (".,. illuslralion) . Secure it In place with Ihe clrclip. making su re it is propertysaaled in its g.oove (see illuslralion) 49 Slide the th.ust washer onlO Ihe shaft. followed by the 5th gear pinion and its bush. making su.e the dog holes in tha pinion face the dogs on Ihe 3rd gear pinion. and Iheoil hole in Ihe bush aligns wilh the hale in I he sIlaft !see illustrations) . so Sfide the 2nd gear pinion onto the shaft, followed by the plain waslle. and the needle bea.ing (see illustrations). Secure I he baaringwi!h l hecirclip.makingsure~loca t es

Engine, clutch and transmission 2- 57 wilhihe4thgearpiniorl facing down and hold it aoove a container padded with rags int(l whicllihe pinioo and balls can drop when the shatt isrotal ed. Holding Ihe shalt by any or the Ireefy rotating pinions, spin lhe shalt as hard as possibkt whHe keeping it as vertical as possible (.... illuslrationl.Whentheba l ~are floogoulolll>eirsioisandiniolheholesinihe pinion. t he pinion should drop 011 t he shalt ~,,: IIIUSlrallonl .Takecarenoltoloselhe

54 RerAOV1I the circlip securing the 3rd gear pinion. then slide the splined w ash .... Ihe pinionandlhes.plinedwasf\er(llf theshalt. 55 Removelhecirclipoocurlnglhe5lhg&ar piniorI. lhen sliOe the pinion off the shalt. 56 Removethecirclip securing the 2nd gear pioion. IhensOdeihespiined washer and ihe 2nd gear pinion off the shalt

Outpul shaft Inspection 57 Reier 10 Sleps38 10 45 aoove.

Oulput shaft reassembly

corr""tly in the groove, than tit the bearing oot.. ~ ( .... lIluslmtlons) 61 Chec~ that all components have been correctlyinstplled

Output shaft disassembly 52 Remove Il!e needle bearing oulerrace from the left-hand end ollhe shaft. then 3O.52F1\/e . ~transml ... ion

remove Ihe circli p and slide the needle beat'ng.lhickthruslwasher arJdthe1stgea.r pink>n 011 the shalt (see lliustrallon) . 53 To remove the 4th gear pinion II is nec/lSSPl)' 1(1 displace Ihe SI&eI balls for t he positive neutral system from the sial! In the shalt and inlo the holes in Ihe pinion using canllifllQalforce,$upporltheshaflverlicaily

58 Durlngreanembly,apply~ybd ...um paste or 1IrlQ"",0<1 to the maling surfaces 01 Iheshalt pinions and bushings. Inslal l the bushings wit h t heir 0<1 hole alignedwilh the hoIe in iheshaflWhenlnstalilngth8circllp$. d(lnot e,par.d the ends any lur1her than Is n""essal)'. and install th8m so Ihat the chaml ... ed side laces the pinion ilsecures and the open and. are in a gap bfltwHn splirles (5 ... Illustratlon 30.15) 59 Slide the 2nd g.ear plnlan onlO the shalt. lojlowed by the splined washer. and secure

-

outputsllaftcompon&nls I cagedbalJbearing

~ c::~~1t

.-

42nd(l88rpinion 5 Splinedwasher 6Circlip 75rhgearpinioo

9 Splinedwasl>er IOlrdgear pinion IISpIinM1washef 12CircJ;p

134thfllWp/rJofI

:~~~

2

2 - 58 Engine, clutch and transmission

lhemin~wiI!!l!>&cirdip,ma king",,",~is

properiyseeted in lis groove (_iIIu$tmtIons.

60

Sl id e l he5lhg~ r pinionon l otheshal!

wilh;tsselector l orle shalt. loIIowed by the

spjined washer.aod:;ecurelhemin.,.acewi\h lhecircip. maltingsura~isproperly ... ated in ItSgrOOV9 (see lllustratlonsj

w~h4~r::':'":

X

:~:'o~~

:: ::t:e pinion On the selector lorl< groove) IHe lIIus\rallon30.3Ia) .Filoneoflheposilive neutral system balls Into&ach 01 tile holes w ilh the narrower oUlskle diameter (see illustration 3O.3Ib). To stOP lhem from CO<1t1nuously r olllngOUI,squl"$ornecl~n

engine oil Into eactJ 01 t ile dfillings alter tile ball has IMM Instafled. Do oot """ grease as tlleballswiliSlicktoomO)Chandilleneytral syslem will not wor!<. Holding tile shaft ve"icalaoothepinioollat.slidelhepinion oniothe shaltwilhihe seleclor'orIe
""""Ie

31 Selector drum and IOfks removal,inspectiolland illstallatioll Note, Acca.s can be gained to the geagineln the frame snd the ckJlch """""""'(_Sectioo20~MolhfKopenJtions

require theengif16 to be removed and the ClWlkcssesrobeseparated.

Removal 1 Separate the crankcase ha lves Irel erto

~=!:;".,r:.=~~~ and larks are 2 8eforeremovingtlleselectorforl<s,note tlle

::'~kl~Oe:;a'::ionwhich way round tIIey fit

Engine. clutch and transmission 2- 59

31.3a Withdrawtlleshatt(arrowedj ..

.. . sndwllhdrawlheguldepln

31 .4& Remove tile splil pin (arrowed) . .

31.5 Bend beck Ihe lockwesher tab (,mowed) ~nd remove the boll

31.6 Unscrew the cam piungerboll end remove il with the spring and plunger

2

31 .7 Remove Ihe circiip securing Ihe cam, Ihen slide Ihe cam (arrowed) otflhe drum 3 Support inglhesel6Clorfo.kson l haforl<. sha!t,wlthdrawlhesha!tlromlhele!t-hand slde of Ihec.ankcase. then remove the fOtks (s.... illuSlr,.lions).Once.emov&dfromlhe crankcase. slide lhe for\(s back O/1to Ihe shaft m tl\e<.corroclorderalldway.oulld 4 Ramovethe split pin Iromthe lOP 01 the guidepinonlheselectorlOtkwhichlitsaround the seleclor drum (see IlIuslratlon). Disca.d the split pin as a new one must be us&d. W~l\cIra.wlheguidepin(s ..... illustration). 5 Bend back the tab on the lockwasher 5(lCuringlhesale<:lo.drumguidet>oll.lhen

~;es~:~;~:h~'\f(~~: i:~U;I,~~oe~k~~~a~~ damaged 6 Unsc.ew lhe cam plunger bolt and .emoYf! il with its spring and piungef (see illustration) 7 Remove the circlip $OCIJring the cam 10 the nght-hand end 01 the drum (see Illustration). Remove Ihe cam. noling how I he pin in Ihe drum locates in the slOI in I he cam (see illustration 31 .17b). Remove the pin lor safekeeping ~ ~ is loose 6 Withdraw the salaclordrum f.om the lelthalldsideollhecrankcase.slidingthe~actor

IOtk off the drum as you do. On 550 models. the longer side of the 1011< boss laces the lelthand end 01 the drum (see Illustration). On 750 models. the longer side of the lork boss facas the righi-hand end Of tha drum (see Illustration 31.16)

Inspection 9 Inspact lheselactor lorks for any signs of wear or damage, espacialty around Ihe lork ends where they 8!1gage wilh the g roove In lhe pinion. Chackthat each fork fitsCOlle<:tty in its piniong.oove. Chacl
2-60 Engine, clutch and transmission

31.14 Chec k Ihe needle bearing in the crankcase lorks are benl. II the lorks are In any way damaged th<Jy must be replaced 10 With the lork engagad with Its pinion gfoove. rneasure the lork-to·groove ctearance using a leelergauge, and compare th<Jresult to th<J spec illcatlons at the beginn ing 01 the Chapter (see illu stration) . II the clearance exceeds the service limit specilied. measure th<J thickness of tl">e lork ends and the width 01 the groove alld compare the readings to the specilications (saeillustrations) . Replace whichevar components are worn beyond their specnlcations 11 Check that the lorl<s m correctly on their shalt . They should lTIO\Ielreely wUh a Hght fit but 00 apprecfable1reeplay. Check that the lorksh alt ho les in the cra nkcases are not WOfflOfdamaged 12 The~ectOfforkshaftcanbecheckedl0f

tnJeness by roll ing it along a flat surtace.A bent rodwillcaused ifficultyin~ectinggea~

and m ake the gearchange act ion heavy. Replacetheshaft il ilisbent. 13 Inspect the selector drum grooves and selector lork guide pins lor signs 01 wear or damage . Measure the width 01 each g roove and the diameter 01 the corresponding lork guid e pin and compare the results to the specifications. II any componen t Is worn beyond~$servicellmit Ofisdamagad . itmust

be replaced. 14 Check that the selector drum needle bearing rotates Ir8f!ly and has no sign of fraeplay betwaen It and the crankcase (see iltu stratio n). Rep lace the bearing if necessary.Dl"ihlioutofthecrankcase.ooting

31.16 Ensore the fo rk is fitted the CDn'8Ct way round lor your model (see text)

31.17e Fit the pin into !hedrom (arrowed) ..

, - ~

~.t:J

c!

"'-. . . then locata the slol In the cam over the pin that oocelt has been removed it cannot be reused. Draw or drive the new bearing onl o place,maklng sure it enters squarely 15 Make sure the cam plunQar moves freely in the plunQar boU. and that the s.pting is not womOfdamaged

Installation 16 Slide the d rum hallway into the crankcase. then lit the input shalt selectOffork over the drum. On 550 mod~s, the fork must be IiUad so that the longer side of the fork boss faces the IefH'and end of the drum (sae illus tration 31.B) . On 750 models. the fork must be1ilted so that the longer side of the fo rk boss faces the righ t-hand end 01 tha dnJm (see Ill ustration). Slide Ihe drum al l the way home. then fit the lork guide pin Into the fork, making sore It enlersthe middle groove

31.16 Align the drom so the plungerlits Into the neutral detenl (errowed) in the drum,alld secure it with a new splil pin jsee Illustrations 31.4band a) 17 IIremoved, li tthecamlocatlngpinlnto the hole In the drum (see illus tratio n). Slide the cam onto the right-hand elld 01 thednJm. making surelhe slot in Ihe cam iocatesover the pin (see illuslra tlo n) . 5ecura the cam with thecirclip, making sureil is property seated in ~s groove (see illus tration 3 1.7) 16 Fit the spring and plunger Into the cam plunQar~t.thenflttheboltinlothebottom

of the cran kcase and tighten it secutely tsee IllustratloIl31 .6) . On 150mod~s. a torque selling is specified (S8f! the beginning 01 the Chapter). Align the s&lectOfdnJm so that the neulral detent in Ihe cam faces down and the plunger locates in ~ (see illustration) . 19 Inslall Ihe selectOf drum guide bolt alld its k>ckwa$her intOlhe bottom 01 the crankcase, making Sure the bolt end fils Into the guide

Engine, cl utch and transmission 2- 61

31 .19 Fit th e guide bolt with its tab w asher groove in the drum (see illustration). Tighten the bolt securely, then bend up the tab on the washer to secure it (see illustration 31 .5). On 750 models, a torque setting is specified (see the beginning of the Chapter). 20 Lubricate the selector fork shaft with clean engine oil and slide it into its bore in the crankcase, making sure the E-clip is fitted to the left-hand end (see illustration 31 .3a). As the shaft is installed, fit each output shaft selector fork in turn, making sure the longer side of each fork boss faces the left-hand side, and that the guide pins locate in the outer tracks in the selector drum (see illustration 31 .3b). 21 Reassemble the crankcase halves (see Section 24).

32 Initial start-up after overhaul

1 Make sure the engine oil level is correct (see Daily (pre-ride) checks).

2 Pull the plug caps off the spark plugs and insert a spare spark plug into each cap. Position the spare plugs so that their bodies are earthed (grounded) against the engine. Turn the ignition switch ON and make sure the kill switch is in the RUN position, then crank the engine over with the starter until the oil pressure light goes off (which indicates that oil pressure exists). Turn off the ignition. Remove the spare spark plugs and reconnect the plug caps. 3 Make sure there is fuel in the tank, then turn the fuel tap to the ON position and operate the choke. 4 Start the engine and allow it to run at a moderately last idle until it reaches operating temperature. Warning: If the oil p ressure light doesn ' t go off, or it com es on while the engine is running. stop the engine immediately. 5 Check carefully for oit leaks and make sure the transmission and controls, especially the brakes, function properly before road testing the machine. Refer to Section 33 for the recommended running-in procedure 6 Upon completion of the road test. and after the engine has cooled down completely. recheck the valve clearances (see Chapter 1) and check the engine oil level (see Daily (preride) checks).

+

.Lll..

33 Recommended running-in procedure 1 Treat the machine gently lor the lirst few miles to make sure oil has circulated throughout the engine and any new parts installed have started to seat. 2 Even greater care is necessary if the engine has been rebored or a new crankshaft has been installed. In the case of a rebore, the bike will have to be run in as when new. This means greater use of the transmission and a restraining hand on the throttle until at least 500 miles (800 km) have been covered. There's no point in keeping to any set speed limit - the main idea is to keep from labouring the engine and to gradually increase performance up to the 500 mile (800 km) mark. These recommendations can be lessened to an extent when only a new crankshaft is installed. Experience is the best guide. since it's easy to teU when an engine is running freely. The following maximum engine speed limitations. which Kawasaki provide for new motorcycles, can be used as a guide. 3 I! a lubrication failure is suspected. stop the engine immediately and try to find the cause. I! an engine is run without oil, even for a short period of time. severe damage will occur.

Running-in recommendations up to 500 mites (800 km) SOO to 1000 miles (800 to 1600 km)

4000 rpm max 6000 rpm max

Over 1000 miles (1600 km)

10 000 rpm max

Vary throttle position/speed Vary throttle position/speed. Use fullthrotlle for short bursts Do not exceed tachometer red line

Chapter 3 Fuel and exhaust systems Contents ~; ~~;!:;'.g~=~=al~~

"::::.:: ~~.~.~t:-,~ ... 15

Altsucllonvalves(USm:xleb)-generallnlormallon

Garburenorovemaul·geoerellnlormalloOl.......

. .. 5

Carburettors·disassemb/y.cleaniogandinspection ........... CatburenOf'll·"'''''''''"'b/y.fIoat heightaodiuel ..... lllchIK:k ...... Carbuffll1ors-removal end install8tion CatOOrettors-sepa,ationandjolnlng.

=re=:==~lai~ik,;,

~:::::~c~k~~r

...... ':::::: . ~~.~~~

7 9 6

F..... ltanI
8

IdleflieValrmlxturaadlustment-generallnforrnation

~~.h.~t~~

Evaporafive emission oontml (EVAPl s)'S\"'" (Califomla lI"IOdels) -

Exhauslsystem·removalandinstallation ..... ...... , ........ 13 Fuelhose-repiacement. _Chapter! Fuel9iI"9"andl ...... senSOf - checkandrep~ement .seeChaPlere ............... 2 1 4

=E~~·~=:ta;,~;~:.:·:::::::::·=g=:~i

g8lleralirlormatlon

Degrees of difficulty

Specifications

3 Carburettors 550 models

~

.....

750 modes

:::

KeihlnCVK30

"'mm K.mlnCVK32 32mm

CarnurettOf adjustmellts Pilctsctew...tting(lumsoul) 55O(UK} .. __ • . . . •.... ..

750Cl,C2.C3andC4models(IJ1<)

r.50~5=!I.~Is(UK}

:~~~.:'

Idtespeed .. ", ....... . Syn<:hrooisalionvacuum

13J41021f4wmsout 1 5181umsout 1112 1\.msout ,~~

15.010 17.0nvn 0.5 mm below to 1.5 mm abo.e 1\oaI bowl maHng surtaoe SHCI\ajlle,1 SHCI\ajller1

3- 2 Fuel and exhaust systems

.

""" "''' H. "" "

Jet si:zes - 750 models PiIotj&I. PiIolairj&t

"

oot availab!e

~eed..!:. g.~.~=modeIs

..

Cylinders 1 and 4

N1GK

CyI~2and3

"" ., " "H.

Malnje1 Cl .C2.C3andC4mode1s CylinOOrsland4

C5C:~~3 Cy\ndersland4

~

~21W1d3 Malna ~je1

Starterje1

Torque setting Cy1inOerhead lnrakelldaplarbol1s

1 GeneosIinformationand pn!CIJutions

General informa tion Thetuel system consists 01 Ihe tue! tank. ~~~7.'oIl~hecarburel1on.tue! "=t':::I:': incorporates B li~ar which sit. Thecarburattorsusedonailmodels8"'CV

=;e:~:::h~~:;':~~;; :~~;ntr"'s an enrichmentc ircurt in

All except USZR5SO Bl Dod B2models

Precautions

.&

:~~~;~'f~~~2e!;!:

won. on any part of Iha r"" SjlSl"",.Don'fsmolte Ol'-"'>wopennarl"lfl OI'bare/iol>tbulbs nNr lhe wonr_, and don'tworl< in e garag a wheree na l"ra l g u-Iypeeppl;ancels />IWsent.IfYOIIsplll a ny flHllon yo"r skIn, r/ns, II off Immediately wit" SOllP lind wete , . W"e n you perform anykineJ ofw",* on t"a flHll sysle m, wu, safaty glasses endha .,. a fira fMac /N$ B lypefira u llngu/sh., su/t_ (r/amm8bIa/iq
Nevarwor1< in a building containing a gas

=..a~lJflI~ugeop«at!ldby.levelsenso<

~withapilotlight.orany01herlormoi

UK ZR550 84 . B5 and 86 models. and UK

naked ~ame. Ensure lhere are 00 naked light bulbaoranysoueesoillameOfsparksnaarby. Do not smoke (ot allow anyone else to

ZR7SOeJ,C4.C5ardD l modeisarefittlldas standard with a carburettorheati rlg system: ~:=ebeen SUbseqUen\lYfittedon

sme>I< " )whi~in t hevi(:in;tyolpetrOl(g a soi ne )

ot otcomponants containIng I!. Remamber Ihaposslb~PfflS81">C8olvapou 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 po
:;.a~~:;:: r"""""bar to k""fl rts cap Read the Salety to,t! section of this manual caref\J\lybefore5lariingwor\<. Owners 01 machinas used In tlla US. paniculartyCalitotniB,shouldn01e\hat l t!elr machines must comply at all li mes wilh Federal or Stale leglslaHon governing Ihe parm ~i blelevelsolooisaaodofpoflutants

s uch as unbumt hydrocarbons. c arbon

~~·v~~~:' ot;&r:;I ~~

I:~

:i::. ! ie comply with leglsfatlon In force at the date 01 manufacture ar"ld must not s ubsequently be altered In any way which will a!fecl thalr emissionolr>Oiseorolpoflutants. 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 isconne<:t the battery. negat;v.(-jtermir>alfirst. 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 btacl<.t..-.dllght.,.thebrackelbolt"....,ure/)' 1_lIIuI.... 1ioo12.&I.ChecI<1h8tthelronttnd

sk:le lank"" bbM1ra,.lilled . thenca,efully 1owfIf1heru.ttrilnto~.maklng ...... therubtllnr.Mlllnlnplacel_illus.... tionj. 8Wilh 1het..... .-..:t.t tn. ...... altactlthe wa ..... dr..... hoM. the Iu.I hose and the vacuum ....,.. to IhIOr unions t_ Hru. ...atton. 2..4b_.,. Onrnodlllswith. Iuelgauge.•ltachlhe ....8Of0¥erIIowd ...... hoM and ~t the sensor wiring corw>ecIor t........tnotton.2.4<:_d). On Calilomllo model •• III.ehthe EVAP system

-

' - . M............ ' - .... fittedr.-yonto

_\llai, uniooa "nd HCUfed by thel'elamps lower the tank IndChaCk th.1 it is properly SMiladandtsnotpOnchinganyr::ontroicatMes orwl'H. CIleCk tMt the,. II no sign of luel

..

, m.taNthetankmountingboltslWld tight.,. 1IlemMCU"et,r t_Wlus.... tlon) .0 Comact.theblltt.-y,fittingthenagatiYel-) tarminalluI . Stafltheenginetndch«:l
: -• • no.oI1 .... _age.lt.lshutif tl lMl" _ _ tatldtheaidepan.e/lt_

",-n

Fuelr"p t.p IIIOuId not 1>11 ,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).ChecI
poir1lao1v.,.t lo_eall t,acesoidirillOd I..... Mdimenl. Check lhe gauze lor holM. II .ny .... found .• newlapshouldbelilledM the lill........ noI""~indiYiduaIy.Fluah I"OghI\flsh-pc*II:~1IYcoghthe1ap\o\1h

"....

\

,~

~'

\(j~~

lapm.yhelpl'H m"'strlllons). II". kage persistl. ren"IO¥I1heSCf8WII and disassemble lhetlljl . no! lng how I'" components fit. CIMn I II components using a high flas~-polnt aotv.m....:llntpat;t thflmforw...... ord!Jm.age R~lCetl.. O·rlngI8ndgalket.what ...... Ihfllreoodit!on.".nyol!"'othe<~1S

.... worn or

dam8Qld. 0< If lhe t.p ilstill taaklngwlth new O-rings and gaskat •• new

Iap ...... balitted.

Fuel and exhaust systems 3- 5

Installation

IdlefueLlumixlureandbesurelhemachin.

17 CI\eck the eondition 01 the tap mounting bolt nylon washers and replace them il ~:~ or deteriorated. Do not UH &IHt

18 Inslall the Iuet tap In to Ih_tank. using a new O-~ng ~ neoenary, end tlghteo ilS bofts securely ( _ lll uslratlona 2.14t:,b and a) 19 Instsllthelutltsnk(_abovs).

3 Fueltank cleaning and repair

2 The pilot screws are set to their correct posillon by themar.ufllCturer and should nol beedjusted.......,. ~ Is necessary to do !IOler I carbureu or overhaul. lithe screws are adlusted lheyshould be reset to the settings speel1led at tht beginning 01 the Chapter. 3 It the englneruns extremely rough at Idleer continually atalla, and ~ a carblxettor overhaul does not cur. the problem, take the

~ ::~o~~~~~~:e ~::~:~~~~::r'.!

~

1 All repairlto lhefustlank should becarfied 01.11 by a prolesllorlsl who haa experisncs in this critical snd pottntiSlty dangerous worir.. Even alltr cleaning IIfld Iluahing of the fuel system, explosh.e lumts can remain and ignitedlitingrepaJr ol the tank 2 ~ the Iutl tank II r&mQY05(i ,,"om the bike, it sIlouldnotbeptacedlnanareawtlefesparks or open fIiImn could Ignite the fumes coming ootol the tank_ Be tsptCially carelullnslde garages where a natural gas-type apptiance is Iocated,becauselhepilot lightcouldcause anexplosion 3 Flu$hllWldelNnltlttnus;ngatoghllashpoiflt sohItnl. Mike sure none 01 the oose unions.eblocl<ed.

4

doe$n·texc.edltlt...-ossions~.

ldIetu.llairmixture adjustment genera l information

1 Dus to ths Increas.d emphasis on controlling motorcycle Ixhaust emlssklns, certain governmental regulal ions havs been lormulated which directty affect lhe carblnlionotthisrnacl*>s.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 thtcarburetl
A

~~~~:~~I~_n ;:ClIo~h~

R. molfal 1 Remove the fueitank end ~s bllCket (HI

S«tion2). 2 On 550 models. careful!ypuleac:h air rdter housing end cover away Irom the housing (_ illustration).

3

3- 6 Fuel and exhaust systems

6.5 Oil connectll>ecarburettor 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 earburett
5 On UK ZR550 84, 85 and 86 models and UK ZR750 C3. C4, C5 and 01 models, trace thecarburet1orheaterwfrlngaoddiscorm&ctit at tnecOMeCtor (... ltlu$lratlon). 6 Slacken The clamps Heuring the carburettora to tl"lt cyiinder head intake adaplersand ease The carbufeltOB off tl\e adapters, noting how they f~ 1_ ~lustration). MiIfIOIIUYI'Ithecarbu"ett
=t

t:::n;:c!~ral:' ~u::':~~

a

Detach ttle choke cable from carbu"en
chBrnberllheOlstackenthedrainscr.wsand draln .. ttle fuel from the carburetlOB. Once allhelueihasbeendrained,tightenthedram ~~

10 1l.-y,unscrewIheSClllWSsecuring the Intake adapters tolhecyl!nder head and rernove ttle adapters and C>rings, noting how theyf~. otscard the O·1ings as new ones must beuaed. Note that the cylinder number lor eeen IIcIapter Is marl<ed at tile top 01 tl\e Inlaka duet - they are not Wlterchangeableand must be inllalledCOITectly.

Installation 11 Inatailation is the raverSl 01 removal. notingthelolowing

... ~e=:::= adaPten

-J

Chedrk¥cracI<sorsplits.ntheeytinder '*'d.ntalo:eadaprersandllirfilferhousing rubbet3.lIIIdreplac8rhemitfllClSS&')'.

Fuel and exhaust systems 3- 7

b}ltremoved,malr.eSU'lllheinlaQ~

_EI$U//I«1eor>kllyus;,g._Q-mp$ (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 marl
outolltlec:a-burettorboc!y l_ilkrstrlltlon).

synehrooisarionandaqU:srasnaeessat)'

_......

seal, if not already removed 5 Where fmed, rlllTlCMlltle screw -=umg the carbtnI10r heal. brack81 Sld pulltleheal.

gJChackIdle'P"dIllldc.rlJwettor (seeChaptarl).

2 Unscrew and remove the top eove<

:~~~o

lind lId/ustments while slill in plaee on lite ll"IOIA"IIing~Oi$nIitrJtlelllacarl:lcNe1fOt"S

tt:::: '::~:f~f:orf::

3

Joe Fuel and exhaust systems

.... lKIrawtlle_pMIIp;n (... _ ~--..y.~ ~

... ito""' ....... pour<:!>

Of •

....

nalI.

lnllonj.

p;n_"

-.ov. n,.

J1N'..........o!y.t>Ot~_ I I~ ... (_ Inu. lra li ""~ . lbl .U. _ tt.._.alve

~=~::.t")"'· r.:>IJI>g""" ~~,"

.U"'OC"W _ _ Ilw .....,jeo """' ....

Fuel and exhaust systems 3· 9

11 On UK models. tile pilot screw can be removed Irom the carburetlor, but nolelhat its sening wil l be dlstlll'bed (see Haynes Hlnrj, Unsc.ewand .emov. the pilot sc.ew along with Its spring, wash •• and a-ring la.e illustration), Discard IheO-ringasantWont

must be used,

~ •

To.-.cOrdthePilotsC",""S CUlTllllt .eWng, tum tllfl

I scr.wlnunfj/itSNb/ightly, coun ting the number of tumsnec....f)'toBChle.".thi., th.n fully un$crew It, On In.ta lla tion, tha sc...... lsllmp~bBC"tdout tllflnum".,. of t um. youv.~,

12 Dttach the VBC!.lum hose and remove the vacuum blankln.., capl, then unhook the clloke linkage b1I, .et ... rn spring from the vacuum take-off adapter ISH iltuslration ), Remove the Ihree screws securing the trokage bal'lothecarburettors,thenremovelt1eouter pla$ticwasher'S l&Hnl...slrlltion9.1d) ,Ufloif the bar, notlne how II lits, and the ironer plastic washtn lMe Ylustrations 9. Ie, band e), 13 Unscr.w Ike chok. plunger nul and witlldraw the plunger and spring I.om tile ca.b ... rettOf body, nollnghowlheyfil. Take :~ not to tose1he apring when remoW1g the

.emove

nylon-bristled bNsh to .emove the stubborn det)Osits, Rinse II again, then dry il with compressed air. 16 Usea)et 01 compressed ai. to b!ow out all 01 the luet and air passages in the main and upperbody,notlorgetlingtheeir)etslntlla carwellor intake 1_ iH...stration) Caution: Never clean the jets or pasuge. with eplfHaofw;"or e drillbit, eos ,t>t,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 andthtolflelinl
=....~=::..II::::::instaJlit>gthe

2 Removethecarboretlors lromthemachine (""" Section 6). Mark the body 01 each carburettor with its cy\irlder location to enSUfe t hat~i , positionedcOl"rectfyOl1 reassembfy. 3 Disconoecl tile Iu&I t3jl vacuum Ilose and r.. move too blanl< ing caps 0< Msas (UK modef.), or filM' and . oction v_ ho$M or blanking caps 85 app'op';ate (US and

~i ~o;:,=.S~~:at~t~~::~~ litwhfn.UnhooI
bar to the carboretlOfS.Ihenremove the ooter plastic waSherS (_ ijluslralion9. tdj .Uftolf the bar. noling how rt lrt • . and removelh .. _ptasticwMhe<s (_ llfustra tlon. 9.1c,

:':..t":I<~ a

not .. Of how Ih .. throttl .. ,eturn

springs. linkage assembly and carb-ur.. ttor synchronisat ion $p~ngs ara arranged to enSyr" that they are fitted correctly on re8s .... mbfy (.... ilfus lralion) . Also oot.. tile arrangementof th .. varklusho$&5andlhelr unior\s.On55(1modefs .dependOngCN"lwhich

~:,:':! ': ~~;~~~;=rV~I~':

chamber s ecuring the th rottle stop ""rew bracket(seeilfuslration 7.6bI. 5 Remove the scr.. ws secu ,lng the carbu, .. tto" to the two mounting brackets and ramove the br!>C 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 iscompresse
:t~h~~;~=. Repeal the procedu re lor

3

3- 12 Fuel and exhaust systems

' t4'.-. ,.

.... ,;;...:J : ,t

~I' O.k

Fit the nMdIe v. ... onto Itl tab on_lIooIt ..

••• makln{j IUralhe needI. va"" lit. Intotha ...., larrowed) ..

O.8 I n.~ lt hanoa t cl\amber

ull",anewoaslr.e ' o.7Ao.t~t

............. t

1~3F1011

2 ~~'-.FIoIIhtIighI "",-,,-,5 _ _

Fuelle llel check IS \.JgI1tyclamplheC
::::,,<>f:,,=.:~-;:.:.~: ""'-.but.t ... ......uonlhatilhigherllW1the

a With tIM IIoat

hIoigh\ cIIeckMI. flt a new IJIII*lOthelloet c:t.n"ber.makingstnl~1t _tdpropel1ylnlbllf""'W.lt*linstaithe dlambWon tlMcartlurattor and tighten ill ~MCU"IIty I_llun-atlonl .

8 Wher.!ittlCl.fiItlMearburatlOfhea\... int<> tl1e CltburattOf body and moont tIM bracket onthellof,t o;\lalnbW l _ lIIu. tratlon7.5) . 10 IllItallthe jet rlMdl.and aprirlgseat Olt<> thediaphragrnessembly l_Wlu$traticln7A, It tnlWllhadiaj)h. agm ....... b/yint<>tha pi l ton~w l thth .ir>dan 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 rnIr1
bOIIomlClgot<>fltleeart>urattOfmalnbod)'. HI ~of_pll..tict.-.g is bein9uHCt.

........ rnIr1
~"":=·lCrewatlhabollom<>f ItIaflolt~.couple<>fI ......

lIw1tum

III Attach Ktowasakl...w::e toot no. 57001· 1017 toltllle Ir.. and 01 tl>eclear pluticlube)lIQIinIt llMcarbura!lOf~.1II

h.... t .. tlon).Ug/"Itlypuah tlMp/ltondown. ~thenaacl ..

ilCONIICIlyNlgnedwith

the naaclla!et.Pr".thadi.plwagmout ...

edoalntolt.groo.... maklng ....... ltil corractIy_td.ChacI
lo1landdownlnthagulOa. 12 Inllall the apring Into tha diap\"lr'9m

usamb/y.mlklng ... raltlocatesCOlTacHy onto the IprIno'Ht. than lit tha top cov ... IMkinglUflltlll top otthaopringtitsover the lug Ol the middle 0 1 tIM cover. and tighten ~ I tctewiMCO.Wllty l_I,,,I'I" .tion). 13 C1Mc1dngltlll luelieveilsadvisedbefora theClrbonfloQ .. alnttaDed(_StapI5onj . 14 Intllllhaeart>urattOf1lt-Section6j.

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

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

~~:mwt

S=bodr 4 B<:momedgeof

Fuel and exhaust systems 3- 13 lheluel tap to the PAl position-luelwill flow

into the tUbe. WartlO!" lheluel level to slabilise. then sklwly klwer the tube unlil the zero mark Is Jevel with the bo!tom edge aI the carburettOf body. Note: Don'I /ower the zero marl< below lhe boltom edg& of the carourellor then bring itbackup-lhereadingwon·toollCCUlllltl. 18 Measure the distance belween the mark and lop of the luel level In lhe tube Of gauge This distance is the fuelleval- write ~ down on a piece 01 paper, screw in the dra in screw

:~~n t~~:~::~ 't~~e~ ~=!:~rt:d check iI the same way 19 Compare your luel level readings to the value listed In this Chapler's Speciticahons. It lheluel level in any carbure!toris oot correct, remove lhefloat chambefand bend the tang up or down (see Step 7),as necessary. therl recheck lhe fuel Jevel. Note: Bending the rang up increases tile fl081 heigllt and lower:; tile fUfJlIevel-bendingildowndocreasilSlhefloo/ heigllt and raises lhe fuel level.

hasbe
10 Throttle cables remova) and instaliat ion

halves (see illustrations). Aemove the cable elbaws/n)m lhe housing, noling tlow they til and hook Ihe cable eods out 01 the pulley (see Illustration) . Mark each cabJe 10 ensure it is

~ ~~=: C:e~~b~~n~~~ti~e ~

RemOllal 1 Remove the carburetto(s (see Se.:tlon 6.

;t~:h~~;"'erendol thecableoutoflts mounting bracket and detach the inner cable from the throttle cam (see Illu stration) Aepeat for the other cable. Keep the carbure!torouprlght loprevantluelspillaga 3 Remove the handlebar switch/throttle pulley housing screws and separate the

machine

:::;:t~:nect routing ofea~ cable 5 Install the cables making sure they are cOlTtlCtlyrout9d.Thecabiesmustnotinler1ere with any other component and should not be kink9dorbentsharpty 6 Lubricate the end 01 each inner cable wilh multi-purpose grease and attach them 10 the pulley (see IlIuslral lon 10.3c). Install the cables into thal/lro!tle pulley housing. making sure theacceleratOf cable Is at the front and Ihedecelerator is at Ihe back. Assemblu the housing, al>gningilS!ocating pin with the hoIfJ in the front of the handlebar (see Jilustral ion 10.3b). Inslall the (etalning screws. and tightenthemsecuruly

3

3- 14 Fuel and exhaust systems

7 lubrlcale lhe lower end 01each inner cable with mulli-porpose gr"""" and atlach them to

' .... itchfchOk. lever housing scre .... s and sepatllle the two tlalves. ooting how the lever

thecartluretlor tlYotllecam lseeit'ustration 10.2J. 8 Make sure the cables are correctly Cl)f"lfl8Cted and locale the ou!... cables in the fflOU"ltingbrackels lsee lthJalration) g tnstallthecarburettorslseeSection6j 10 Adjust the cables ss described in

~~~~~: t~hee ~:u~:gan~se~v::U~;~~lol~~

~!~e\:~ :~~~':~~B~efc;r:.: st&ering to bind. ll lnstaUthelueitanklseeSection2j 12 Start the engine and check that th.idle speed does rIOt ose as th. handl.bars are turned . If tt does,OOfTfICt thfl pmblembefOfl! ridingthemotorcycte

11 Choke cableremovalandinstaUatiOn

houslng and detach the cable nipple from IhfI cOoke tev", lne iliustrlltion) 4 Rernovethe cable from the machine r"IOtlr.g ilscorrect routir.g

Installa tion 5 l""lail the cable making sure ~ il correctly fOlJted. Th
8 Check the opera!ion and adjustmer>t 01 the choI<eca~elseeChapt ... l) g lnstali thelueltanklseeSection2j

12 Airfilterhousiog -

removal and installation

Re mova l 1 Rernove thfl 1..... tanl< (see Section 2).

~ ~~~~~~~;~t~c~~u~::':~w system.

disconnect

the

atmospheric

~~:I~ :f/le;.:~i::~i: ;!i~~c::~ 1evef000sing.making"""' thflca ble ~bow Os

~ ::~tI~t:~~ =i~~u~:~~~~ ~~n:'::.a~ ~ making sure the fits conec1Jy.and the lever

Removal

pOn In the front han locates in the hole in the Ifont of the handlebar lne illustration 11.3a1 InSlaUthesc"' ..... ar.dtightoolhem secureJy. 7 lubrlcat.tI>eiowercable 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 Che<:k tlwlt !he cabl. elbow Is ~Iittedin!he 'witchhousing

1IOw1hot>alf.ringre!...... ""' ~ .. ~1he

~=~h8-::W=:: :: :'~7J·

_oIlIOd1p;p._ ... """", hploce lMe

dlmp "", . ff<>'o tlll cylin
...,..,.. IIle . ysl .... (... W",. "atio<>OI, '-101"

cla,""~ l lllongina!lr

:!.Qt""'....

5 Monoeuw ...... ...IMe ril..._ """''''9t _OUIoIlhe lr..... _ l........ d.

In. t.n.rlon

e ....aII.I.'''''' .. ''''',.....oI..,.,.,..

S
.

r

n

e

I

I

l

~

r

a

""nstom. ....,......... -...- ;"""O::t:*";"''-~''':t;:-n~

..-.....,tIOIt~ ~

""'._H>nl·-"""'' 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_
M

d< "' _'otrw_oI""' ~ont~ ' ~ oir

M .. ""io<> (_

='!...-':'~~"'~,'&(I

a

3 - 16 Fuel and exhaust systems

150 models F~ e ntowgasl<et into eac:h 01 the c)'llode< hoadpoo1. ( ... III... t..tlonl.AppI)I • ....-

' 1nspec! !hebusheslots;g..,.oItt..mage.-.d them II necessary. R _ e the uaM>gmg from em..... the end 01 the siIeneIor

,61>1_

4

Silencers

oIgruM IOIhII~MltokHpthemin"

7 $IK"-'thllldIImp onlhe\Cint bet_the siltncMlWIdlhlldownpipo (Me ..... tratlon).

..

8 ~IWId..-noYe!hesiltncMmountinO

10 In".. the

nutlr>dbolt,thenre4eaMthesilencerlrom the .. hausl downplpo U$&mbiy usfn(l a

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

twistingmoliot1 (_"lust
Itiultraiioni. Align the

_lIninglhlldowr"fllpoit--r. 5 ~!hesyst .... lmoposition"'lNIt t~!Iud 01 .""" o;Iownpipo ~ Io<:et~ In ill port In th. cyllr>de< head (... llIu. tretion t3.2bI.n!hectampoonto theSluds.maIU"og ..... tIMollall-ring'ec .........elnslell.cland theclampoDutt'4>agWosItnem.thenlnstel the ctemp nuts fingoer-Iignt 10 hold the Iystern In ~IK' (s. . lIIustr.tlonl . Support ing the

"-'elhll
"'<;Iamage.RIIpiKe~~.-.ary. ~ .. into lhe downpipo andmal
mounting

.yst",",~ t hes.illlncerlTlCltlntngbrKl<eclt

therewendlnstellhllbo/lwithits_bUI 00Il0l yecl\ghl.... the .....1 ( __ illustration 13.11. Now'lghl .... therr~nut.~. lhentighl .... the """"*nut 'Runthe englneunHilt II warmed up and checktlMo • .,..ternlof ....... A1k1wIhllengr.e

:.c::.=~ten

..

thectemp nuts""

~-":7:=-"",-==:~:::::::

13.10 UMe_SHlingringltrl
Fuel and exhaust systems 3-17 brackf.ltattllf.lrf.lartl\f,tn instal l thf.l bolt from the insidf.l. Tightf.ln the ctamp boll and the Silf.lflcernut securf.lly (see Illuslrations 13.7 end 13.8). 11 Run the engi
16 Manoeuvrs the system into position so that the head of each downpipe is klcated In ~sportinthecyllndefhead(_lllustratlon

13.2b). Fit the clamps onto the studs with the notch In the clamp facing down, making !lUre the half·ring retainers are installed and the clamps bun up against them,then Install the clsmp nuts and tighten Ihem securely (ae. IllustratlonI3.5). 17 Install the silf.lncers (see above) 18 Run the engirlfl until ~ Is warmed up and check the system lor leaks. AJlowthe engine to cool then retightf.lflall theciamp boIis and silf.lncernuts.

Complete system 19 Unscrew and remove the silencer rTlOIXlting nuts and bolls j_IUustration 13.8) 20 Supporting the system, unscrf.lW thf.l downpipe clamp nuts from the cylinder llf.Iad then remove Ihe system from the machine (SHllluslration 13.2a). Note how the half· ring retainers locate against the head of each pipe and are taped In place (SH llIuslratlon 13.2c). 21 Remove the gasket from each port in the cylinder haad and check them for damaga. Replace them if necessary 22 F~ a new gasket into each of the cylinder head ports (aae Illustration 13.4). Apply a smearofgreasetotllf.lgasketstokeepthemin placawhllstfittingthedown~peifnecessary.

23 Manoeuvre the system intopositioo so thattllf.l head of each dow!lpipe Is klcated In Its port in the cylinder head (SH lllustratlon 13.2b). Fittheclampsontotllf.lstvdswiththe notch In the clamp facing down, making SUfe thehall·ringreta inersaroinstallodandthf.l clamps butt upagalnst them, then Install the clamp nuts finger·lighl to hold the system in placf.l (se. iIlU SIrJ\lonI3.5).Supportingthe system. allgn tllf.l silencer mounting brackets al the .oar and Install the bolts with their

waShers but do not yet lightf.ln tho nul (SH illustration 13.8). Now tighten the ftange nuts secur8ly.then tlghten the silencer nut. 24 Run the f.lngine until ~ is warmed up and checlr. the system lorlf.lal<s. AJlow the engine to cool then retlghtf.lfl all the clamp nuts and the silf.lncer nuts.

14 Evaporattveernieeioncontrol tEY...,_~

modetI) • general information 1 TheEVAPsySlem prevents thef.ISCape of fuel vapours Into the atmosphere and functiofls as follows (see iltus!ratlon). 2 Whilst the engine is SlOPped, vapour emitted by the evaporation of fuel In the tank paSStlS throogh a vent ho6e 10 the top of the separatorwheff.l some of It condenses and passes through the separator Inlo the pump unit,buitllf.lmajorilypaS$tlsintothacanister. Vapour emitted from the carburettor float chambers passes through a V9f1t hose directly to the canister. From!here~ can ooly escape to theatmosphefe by passing through thf.l activatad charcoal which traps Ihe vapour compif.l18ly 3 When the engine is started all vapour stored in the canister is purged via the purge hose Into tllf.l akfitter housing where ~ passes InlO tllf.lf.lngine lor buming In the normal way. AI the same time a simple pump. operated by

the vacuum from no. 3 carbure\tor Intake stub,retl/fOS all liquid fuel in tha Sf.IPWatorlo ttle fuel tanlt:vIa theretum hose. 4 The fuel tank filler cap has a one way valve wl\ich allows air inlO the tank as the volume 01 fuel decreases, but prevf.lfllS any fuel vapour from escaping. 5 The syst"." Is not adjustable and can be tested only by a Kawasaki deater. Checks which can be peflormed by the ownefare given in Chapter 1.

1SAkSUCtionvalves (USmodoIoj- _ information 1 The us models Incorporate an air injection system dnigned to enhanCfl the burning of hydrocarbons in the f.I~hausl gases. thus reducing 10~lc emissions. The system employs a modified cylinder head and valve COVef, in which air is drswn through a reed vafyearrang.ementlntottlef.lxhaustportS,. 2 The system is automallc In operalloo and e~cept for the reed valvo check described in Chapter 1,shoukl not require attention. The most lik8ly fault Is Ihal unliHered air may be drawn into the system through a damilged air fiHerelement or leaking hose,making tlckover unstablf.l and reducing engine POWef. Backfiring OrOlher unusuat noises may be

_om.

14.1 EVAP systam. California models ooly (750 ITIOdeI shown, SSG similar) I Fuel return hose (r9d) 2 Vf.Iflthose(blu6) 3 Vf.Iflthose(biue) 4 Purge hose (green)

5 Vacuum hose (white) 6 V/II1/hose(yul1ow)

1 V8pOW"separator SQlni$ter

3

4"

Chapter 4 Ignition system n Genera l informa~on.

. 1

Ignitiontim in g-general informatiorlsndchecl::

... . . , .. , .. , . . 6

Ig nition{m
Neutral switch - check and replaceme nt . . see Chapter 8 p-.jse generator coil assembly - check, removal and insta llation. .. 4

Ignition HT coils-check, remova l and installation Ignitionsystem-checi<.

Sidestandswitch - check and replacement . Spark plug gap check and replacemel'\t

3 2

. , . . , . .see Chapter8 . ... see Chapter 1

Degrees of difficulty

Specifications General information 1-2-3-4, fromlefttoright 1 - 2- 4 -3 see Chaplef 1

Ignition timing 55Omodels UKmodels USmoQals 750models

UKrno<.IeIs

US"""""

12.5" 8TOC 0 1200rpm to 3S' 6TOC 0 700lrpm 13" BTDC O 1200rpmto 36" BTDC 0 700lrpm

12.5" BTDC 0 1100 rpm to 3S" eroc 0 7<XXlrpm 12.5" BTDC Q 1300 rpm to 35" BTDC O 70c0rpm

Pulse generator coil R~sI3nce

550 models ........ . ................ • .. 7SOmodeis . .

At gap 550models ...

4 Ignition HT coils PrTnarywindingresistance 550models. 750 models ., ..... . . . .. .. . ... . ... . , . . , . . , . . .. . Seo:>ndary wind ing resistance(with pl ug cap removed) 550 models 750 models Arcingdistance S50models 750model$ . .

2.30 to 3.50 ohms 2.61t03.19ohms 12.0 to 18.0 K ohms 13,5 to 16.5 K ohms

Torque settings PufsegeneraWrooilmountingpiatescre'N$ • . Timingrororbolt . . Pulsegener.lWrassemt!jycoverbo lts

2. 9Nm 25 Nm 10Nm

,--

4-2 Ignition system

All models are fitted with a lully transistorlsed electronic IGnltkln system, which due to its lack of mechanical parts is totally maintenance-free. The system (;omprlSe1l 8 rotor, ptAse gene
~~~!:.~enginelsrunningandlhe&idestand Because o f th eir nature, the Individual Ign~lon system components can be checked but not repaired. i! ignilion system troubles occur. and the faulTy component can be Isolated,thaonlycurafortheproblem ls to rep!acetheparl with a newone,Keepinmind that most elecTflcal parts. Of1cepurchased, cannolberelumed,Toavoidunnecessary e~pense. make very su re the faulty componeot has been positively idenllfied before buying a replacement part

01 Ihe Two possibilities,the latter is by larthe most likely. In the eveotof failure. check the system in a fogical fashioll. as described ,,"ow

2 OlsconnecTlhe HT leads from the spark plugs. Connect each lead toa sparaspark plug and Isyeachplugonthaeng i new~hthe threadscontactingtheeng ine_lfnecessary. hoIdeachspalkptllQw~hanlnslJ!atad t ooi

Warning: Do not remova any of the sparl< plugs from tlla engine to parlorm this check - atom/Sad luel ".ing pumped out 01 an open $pIIrl< plug hola could /gn/ta, causing

1 .&. •

savere/njut)'/ 3 Having observed the above precautions. check that the kill switch is in the RUN position, tur ... the ignition sw~ch ON and Tum tht\engine over on the starter moto r. If the system~lngoodconditiona regular.fatblue

spark should be evident at each plug electroda.lfthesparkappearsThinor yellow ish, or is no ... ·e~islent , further investig ation will be necessary. Before proceeding further. tum the ign ition off and remove the key asa safety measure. 4 The Ignition system must be able to produce a sparl<. which is capable of iumping a partiC\llarsi~agap. Kawasaki speeify That a healthy system should produce a spark capableofjumping6mm(550modelsjor7 rnm (750 models). A simple testing too l can be made to test the minim..." gap across which thespa""will;ump(seeTooITlp) 5 Connect one of lhe spark plug HT leads from one coil to t1\6 protruding electrode on the tesT Tool. and clip Ihe 1001 to a good earth (groundj on Iheengine or frame. Check that the kill switch is In the RUN positkm, turn the ignilion switch ON and turn Theengiflll over on the starter motor. II the system is in good cond~lon a regular, lat blue spa"" should be seen to jump the gap between the na il ands. Repaal The test for The o ther coil. II the test (estJlts are good the eollre Ignnkln system ca ...

2 19nItionaystllm-check

Caution:Theanargylevelsin al~tron/c

Iystems can be veI)'hlgh. On no account should tha ignition be switchad on whilst the plugl or plug caps are baing held. Shocks from tha HT circuit can be most unplaasant S~ondly, It Is vital that the engine Is not tumlKlov.rorrun wffh any 01 the plug t:aps removed, lind that Ihe plugs illre $<)undly eatfhed (grounded) whilllll the syslem II checked lor sparking. The ignition syslem components (;an b e s"rio..51y damaged if the HT circuit

becomes IsolallKl. I Asnomeansoladju$tm8fltisavailable,any failure of the syslem can batracad to fai lure 0/ a system component or a simple wiring laun

A . . . . IP-*oaplwt*tgfool_ba

macM from ill bIocIr 01 .veld,

ill , . " .

""toI"cllpilllrrdfWD~_O'

wIIII:It""""'.fltilllfill..,.npltlg CilllPOI'~HTlaNandCilllnba

---

~toltland..""a.."..tha

pp barw- tile two fIiIIIII andIIls tha

be considered good. If the spark appears thin or yellowish. or is non·exisTent. further investigation will bene<:essary. 8 Ignition laults can be divided into two categortes. namely those where The ignition system has failed completely. and those whic:h areduetoa parlial fai!ure. The likely faull$ are listed beiow. starting wilh The most probable source 01 failure. Work through the list systematically. referring to the subsequent sections for lull details of The necessary checks andtesl$. Nole:Bfl~checkingthefollowin9

Ilemsensure lhetlhebeNeryisfullychsrged andlhataJIfusaslr8ingoodcondifion a) Loose, corTOded or damaged wiring cormections,t>rOI<enorshort~wiring

between any of the component parts of Ih6 ignition system (see Chapler 8) b) Fau/tyHT/eadorsparl
==:OfincomJCtgapbetween

cJ FaultyignjlionswitchOfenginekillswitch (see Cllapter 8). d)Fau/tyneutralorsidestandswltch(see Cf>apfer8). 8) ~7: pulse generalOfcoil Ofdamagad f) Fau/tyignitionHTcoiI(s). g) Faulty ignllion control unit. 7 If the above checks don't reveal The cause oltheproblern.havetheignilionsyslem tested by a Kawasaki dealer. Kawasaki produce special lesters which can perlorm a comptete diagnostic analysis 01 the ign ition system

3 fgnttion HT coUs - check, removal and installation

Check 1 In order to determine conclusively that t1\6 ignITion coi ls are defective, they should be tesled by a Kawasaki dealer equipped with t1\6 special diagnostic tester 2 However. the coils can becl1eckedvisualty (for cracks and other damagej and the primary and secondary coit resistance can be messured with a mul!imetel . If thec04 ls are undamaged. and if the resislance readings areas specilied al the beginning o f Ihe Chaptet,theyare probsbty capable 01 proper operalion. 3 Remove the seat (see Chapter 7) and disconnect the baltary negative (-) lead. To gain access 10 the coils, remove the luel tank (see Chapter 3j. The coils are mounted on the frame tubes (aee IlIuslratlon 3. 10). "Disconnect the primary ci rcuit electrical connect~fromthecoilbeingtestedandlhe

HT leads from the spark plugs (see illuttrationj. Mark the locations of all wires and leads beforediSCQl1nectlng them. 5 Setthemelertotheohms~ 1 scale end measure the resistance between the primary circuit term inals (see illustraTion). This will

Ignition system 4-3

giYtI.,...;stanc.rNdingoilhepnm.ry wind. . . and should be consisl ....1 wilh the v.l .... glv.., in the S!>'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<;t one ma t... probe to on.e Hllead and thaother probe 10 the olhertead !sae illustration) . 11 tlMoreadingoblalnedl.nol wilhintherange =!,~lications.jl islikeolyt/"lalllMo

7 ShouId"lher 01 the above checks not produce the aX!>'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.8
7SOrnodela.8Isoremo:welheright-flendaide peneI(_Chapler7). 2 Trac.lheiOnitlonpulMgenerllorwir!ng beck and discornec1 ~ al the igliIion control unrt(550rnodeII-removelheunitlotacc.u IOlheconnectors-"""Sect~n5)or'llhe

COMaclorbellln(llherighl-h'nd.ld.PlI .... (750 modal.) lsea Illustration) . Using I

4 Pulse generator coil assembly - dleck.removal and illstallation

~ ~~:~:7;e:~~~;,~,;~~.o:~.:.,t~a ~:k ~

=1;~~I&rmjnal.onlheCoilsidaot lhe

3 Compare the reading obt.ined with thll

Check

or->lnlheSpecffic>llion$althe~oI

1 R.......... lIMo seal (see Chapt. 7) and diaconnecllhe battery fIIIO'IliwI (-) INd. On

ttwCtlapt .... The pulsegeneratOrcoil,,-.., be repIaced~tM'eadingoblained ditI.sgt6ltly

tNty.ltmutlbe~tMcmis.seaIed

=

1ri8
• I

..tnlnaccura l.second.'Y winding reading could tNo dtMloanHTIud _ _

IheHT";:=:~='::;::

connectlon.1 t1.. coli end make Ihfr ~'Y winding lesl across th. HT '-«JI_"'''-Ih.,.ed/ng$llouldbe ~IIyIHlUlanfl>e$pftCifNdrlflU'"

Removal e R_llheuat(seeChapl.7)1tld disconnIocI 11-.. bellery negatiwt(-) INd. \hen

~=~:.==t!..'ubea

!see mu. lr.tlon3 . • 0).Disconnecllhe prinwy cIrcuiI electrical comeclOl"S !rom Ihe coh (.... III ...t .. tIon3 .• ) anddiscomectlhe HT leadl 'rom lhe IPlIrlc ~"IIs. Marlc lhe locallon. o t ,II wlrOll 8nd "'ads betOO'. dilcoMecting thl!m. to Untetew tM lWO nuts secuiflg eac~ coil. rooting theNtlh (Oroond) l""",n.aI S8Cl,I,edby The ' rontnutlot l helel1-~coiI.andr"""""

theooill C_illustratlon}.Notelhllroutingol lIMo HT 1Hds.

~ .I I.

-"'jtw

,

-'1' ~ -

.0

.

!

-

~,

~-

.

~

3..10 Eechcoil la securedbytwonula C. rrowedj. Hotelhe . etlhtenninel secured byotl8otthe nuta t4j

" ~. 1.2

On750modeIsfl>ew1rlng~tOl'Ia

behind the right-hand side pIMI

4- 4 Ignition system

from lhat gr...,. j)IIrtk:u,,"rty ~ !he meter in(Iicales • ahort cin:uit (no mNSUfabie resilltaoce)or..,opencln::uil(lnlinit".orW1f'/ higI'I.esist.nce) 4 Hthepoisegeoeratorcoi!"lhoughItobe laulty. II.SI C~fCk Ihal 1~l s II nol dlH! to a damaged or I)roken wire lrom the coil to the ConrleCtor; pinch..:! or brok&ll wires c an usually be '''Pl!lr«l. Note t~.t Ihe pulse generator coil "notl"ailable indMduallybut com" In assambly llong wilh Ih" """-"lIingP'-laJild'lMng

.1

Re moval

(150modeII)(IM illullrllion 4.21.FfMlhe wlril'lglromanyciplorl~andl_1I

itwough 10 the o;oiI. 7 UnlKr.w lhe txMlS securing the pulse generatOfasaemblyCOV8ftotherighl-h.rxI side of the crankCua (. .a lIIuslrallon)

:!:"'o: :a~~~.8Card the gasket as a 8 On 150mocIeI•• rtmOVethe screw !IeCIIfing

:,;;:r~=t:,in":::th"oIlprenu r .. , Remov' the tllr. . SCrews securing the ptMegeneratOrcolasMlTlbtyrTIQ\rIIiIgplate

5 R_elhe . .at (IHCIoapI.. 7) and

10 the crriCIIH 11M Mlu. tr. Uonl. Ramow IherUJberwlo1nggromrn.tlromitsrecasln

On

thecran~H_,lhan.......ovelhecoil

~llheballl-rneglitlYe(-)Iaad_

750modets.atso..,..,...1herlghl-r.ar.lsiO& pa.t!SMCIIIpIlrn. II T..,.thelgnltlonpulH~atOl'wiring

back and dIscoMecI

at the IgniIion control unit(560moo:tet.·f...-.oYelhe .... l lorlOCCe$S 10 IheconnectOl'. -_Sactlon 5) or 8t lhe connector behind IhoarIQht-h.rxI side pan.. ~

~,noIInghowltlits.

10 hamlne thoa .OIorlor signs 01 damaga and .~aca h II MC ..... 'Y. To remove 11>1 rotor,""'.17mmaparo>lO'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 remove
SPl!nner to cOllllter-hoid the rotor. InSlall the r010r boil and light.., ~ to the lorQUO sell'ng spac:If*t.t Ihe begInrW1g of IhII Chapter (.... llullrallon).

12 ~ I amur 01 ...Iaollo lhe rut.t..r wiri"ll MII...cI IiI It Into Its re<::ass In Ihe c.anl
swolchwnlOitstermirlalontheswitchand tight.., the ICftW lOICU"eIy. 14 "«*"! • ...-OIlNlantlothecrankc8H joInlsonthepuisegeneralorassemblycov.

Ignition system <1 05

mo,Ing_""" I....

iII~ot'.tlonl.lns l ..

tt>o

poMo_.''''~C..-"'''''''.'-"

__ _ s.an "'"

goo""otorKl liijlrtonitsbollSI0 ' ,,"Of*:;/\o(I ~_~~-::~~':l

_

~

~in

~

C- _ .. _

~ , ~

_

••
te _t'l>etoo" OI)'MgO' ....

Hle;>
..... _.lllhesea' _ _ p.noll750 ~1_CNp\er1)

159litiot1con1r01un11-c:heck. removal and instaIIalion

' H ..... ,.............. in""'~s.enor.

n...1_ to iooIate ' """"",,,,cI on ¥vi"'" 1M , ~ Is lilolQrOloonoonlrcl uniI

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

l<--...;.l_foo-teOling.

5..lThe~aI_"..-.nted

_Il10-..,

4-6 Ignition system

it ~

Generallnformation l Sincano~.xlsIslor.qustingtlwl

Ignflion liming and linea no componeol is a.utlj«IlOmecIIInicIII_.n-. .. ".,.-I

4 UnlC'_ the boll. HCUfIng 11141 poise

:::=k~=Ir~:: \~I~~InI't:;':.~

:,dlhegll"'lt •• ,,,,,w_muSlbe

5 ThellmO'lgmlrllonthilrotor lstlwllinene'" lollwiettlrF.....,.",kdc;oolestlwlfiringpoinl .1 1d1.~lorcylindtt""".I...:14 t... lIIullretlon). The lIat>c tlml!\{l mark with ~.!:.I"l'IOuldallgnls tll4lprotru"","OO

lDt regularcMc~QII/y~""""tlgating alault

s uch as. IoN; 01 po_Dt.mlallre. $houkI ll>e ignilionllmlnVbechlcked 2 Theignl!loo t lmi!\{lIsClllck«ldyn amica l~

(enllinerunnw,g) Ulmo .t!robos<::opic lamp The inexpensl\lfl neon lamps should be adequate In Iheory. but In ,,",clice may p!Oduce.puiMoIllUCfllowlnlensilylhet tlwl liming ...... k ,...,.1 ... Indistinct llpossi". oneolthe~predHxenontubelamps

II Connectlhe tlmlngllghttOlheno. '

=-ac:;a~:""described

In 11141

should be UNd. powe<<
7 Start the lrIgIne.ndaim lhelighl II Ihtt

~ollheappropriatIYOllagoe. Note:Do

~tWo*>gmerlt.

noluselhemach/tle',ownballeryasitll

II

Incotrecl rNdinf1 ""'Y ,.wli /rom sirey

W~h

11141 macl'llnol idling II 11M specitl«l

~1hetWo*>gmlrllF~eigo'\_1I>e

Check

It8t1c1ln'i1gmerlt. 1nc:,UUllMfilginespeecj whil.1 observing lhetlmlng merI<. The liming mark should mo". anll·clockwl ... Inc'laslng In

3 Wsrm thell\lllneup lonormllope,allng tempenllure tn.n , tOllIt

'~81101'1 10 tIM 1!\{Iln. ape«! 00111 Mlt(/;oanc.(nok*lt~llonmark)

/mpuIse~wllhtnlhemach/tle·s~triuI

$)'$*".

o Slowly

I ,eaches

10 At.I, •• dy"811d.lhefeisnomean.ol adjutlmlrlt of Ihe Ignil!on liming 01'1 Ihtt$I ~."1he1grillon1ln'i1gIsincorrecl.Dt

tutpICt«lol being Il'ICOfTect._oItlM IIJni!Ion 'yalemC<Jn'OI)Onentsis at lau~ .•nd lhIayalemmwtbetftt«lasdllsaibodintlwl ~s.cuon.oIthi1~er

11 W'- lhe chedt it complete. apply • tmeMol Halant to Ihec,ankcaSlljoinlsOl'l the puIMII_IIOf nsembly (:0\1'" malmo ,url.ce t' " IIIU t lr. tlon 4. 14a). InSlall the pulsegener.10flIHM1bIyeov«usioganew lIaskatand llllhlenil,boIlslo lhe!I-peCilled lorqoeeetting t_ III". lnItlon4.14b)

5"

Chapter 5 Frame, suspension and final drive Contents Row:;llockabsor'bers-removal,i\spectlonandlnstallation. .

10

Rear s...spensionbe8r1ngs- lublication .&eeChapt.. " R6arwheeleouplnglrubberdamp&r . . . . . . . . . . . . . . . . . . . • . 16 Spmckets - cIled
.............

~::::=~nsrallatlon seeChaprer~ ~::::= :"::~~w;:\=r~=.:u ~ Steerlngstem - removalandlnslallatOn ,.

..seeChapler

. .. ... • ,..

6

~~ i~.,;;~t;,;.,;;~' ~i :: .... ~~.~erl~ Swinga'm·'....".,.aIMdlnstallation. .

" ••. 12

Degrees of difficulty

Specifications Front forks for1<

o~ ')'PO! •••••

F";"SOoil,,:it)I

Oilcl\ao:lge ................... . 7~=forkOV ........ ulfcOOlpj .. te/y dry)

""~

40810416cc

Cl and C2 models Oi ehange." ............... " .... . FoIlowtno IO
C3.C4andC5 models o;ICMflgEI . __ _. __ _._ .....

ot:ing Icri< <>Vefhaul (compjelely dry) OiIcnange." .................... . Fork oIIF;::;;.... fork oveI'haui (cornpielely d'Y)

417cc .OO~

""'~ 463lo471cc

550 models

750 models Cl and C2 models ..

~,~~.C5~I~, ....... ____ ._ •.. .. . " "();I _

... __ •.. ... 11110115mm' isl7llJlJSlJf8dlromthtl rop oft1le lube with rhelori!springremovedandlhelub6fu1Jy"""",assedinrIMsIi<1f1'.

•

5-2 Frame, suspension and final drive Front forks (continued) Fork spring free length (min) 550 models Standard . Service limit (min) . 750 models Cl and C2 models Standard . Servicefimit. C3, C4 and C5 models Standard. Service limit 0 1 model Standard ... ....... . ..... , Service limit .

395.5 mm 3a7mm

402.5 mm 394mm 396.5 mm 3a9mm 391.5 mm 3a4mm

Final drive Chain freeplay and wear limit . Chain size, no. of links 550 UK models .. ...... ....... ..... ...... . . , .. 550 US and Canada models ...... ..... ...... , . . 75Qmodels ....... . . . .................... , .. Front sprocket diameter - 750 models Standard . Service limit ... Rear sprocket diameter - 750 models Standafd . Service fimit .. Rear sprocket Wafpage - ali models Standard. Servicelimit ..

see Chapter 1 520 a-ring type, 106 links 520 D-ring type, 10alinks 525 a-ring type, 1Cl6links

65.58 to 65.78 mm 64.9mm 187.02 to 187.52 mm 186.7mm less than 0.4 mm 0.5mm

Torque settings Brake pedal pivot bolt 550 models 750 models. • . Gearchange lever pivot bolt Handlebar clamp bo~s . Fork clamp bolts 550 models . . . . . . . . . . . . . . . . .. , 750 models ............... , Fork lop bolt .......... . . . . . . , Damper rod Allen ~t 550 models 750 models. . Steering stem bott . Rear shock absorber lower mounting bolt and nut Swingarm pivot bolt nut 550 models. ... •.....•..•• .•.•.••.........•. • .. 750 models. Brake torque __ _arm nuts 550 models ............. .. .... . ... , Front sprocket bolts - 550 models. Front sprocket nut - 750 models Rear sprocket flUts .

10 Nm 9 Nm 23 Nm 23 Nm 21 Nm 20 Nm 23 Nm

29 Nm 61 Nm 39 Nm 39 Nm 93 N m 109 Nm

M~

32 Nm 10 Nm 125 Nm 74 Nm

Frame, suspension and final drive 5-3

1 Qenerallnformatlon

=-=~7~~~>e machine hnaccumulated a lot of

rro'!es. the lrame should be e..amirled clo&ely lor signs of erackil'lg o<splittil'lg at t he waIOed n':::e~s"""aIUNcmdletwin$parstooi Front suspension Is by a pal. 01 COIW&ntlonal oil·damped le~scoplc lo.ka which ate non-adjustable. At the .ea •• a box'$(O(:tion aluminium

=::::':.~~~k~:'::

adjustable lor p<e-Ioad and both compression and r<'!boln::l d a mping. Thed.;-;elothefllar~l,bychsin.A

joints. Looaeangine mount bolts c an C.IlSfI ova1inllOf frecturing of the mounting tabs. Minor damage can ollen be '8$lal'ed by weIe e >ed.rr".~.

3 Remembe. that a f'ame which Is out of a lignment .... inc.use handling problems." mOsa~nment it &uSpected asthotr&SlJ ltofan

"",eident. ~ .... ill be """""sary to . t rip the mach ine completely so t he f •• me can be thoroughly checked.

rubberclamper system(oftencalleds'cush dfive ·)i.filtedbet .... eentherear .... heel COI,Ip/ingandthe .... _

2 Frame· inspecffon and repair

Footrests not .equire att8f1tion unless accident damage hu occu'red. tn most cases.lrsme replacementls theonly !IIItisfactory.emody lorsuchdamage .A t...... frame spe<:lat ist. he"" the Jtgs and other equipm8f1t """Hsary for straightening Ihe 1ra..... lotherequired . t a nda rdol aceurlOCy. bul lIVen then there Is no simple .... ay of , The InImll Should

' Aemove the E-c,p Ifom the bottom 01 tile footrestplvotpin.thllnwttnd"' .... the pivot pin end remove the foo"...t (SH IIlus lrations) On the Ifont fOOj,ests,l'lOte theli1ting Of the "'tum spring. On tile rear footrests, !\Ote the fitlingol the t'NOinterioekingplatM&nd t he spoing(_ lIIustretlon)

SrakepedaJ 3 Unhoo!< the bral<e padal retlnl spring and lhe brake light sw~ch spmg from the brake pedal tMe IlIustrtrUon). 4 Alimovil the spl~ p in 11'0m t he clevis ",n $/Icurlng the brake pedal to the master cyHnder pushrod (..... ;nu .tration).Aem<>V
.....,

5 Unscre .... thotplllotboltsecuring thebrake pedal to the footrest bracket and r""""",thot pedal (_ NI ....trationl . On 550 models. note how thot brake li!.Iht s .... itch lever rrtll. fllnstaliatlon isthe rllVerseol rllmOVll.Chec:k the operation of the ' ea' brake light switch and the hetghtol the brake pedal (s. . Chapter')

Gearchange lever Removal 7 UrlSCfIIW It\e gearcl\arlgelever linkage arm pinch bo/tandfll/l'lOV8lM""" lrom tt\eshaft. no!inganyalignmentmatks(_ IIIustretionJ Hnomark.aravisible.maI<eyourownbel"", removing tile arm s o the! ~ can be correctly ailgnedwithltlesMftoninslalllltion.

5

5- 4 Frame, suspension and final drive

8 Unscrew the pivot bolt securing the gearchange lever to thelootrest bracket and ,emo"" the I""er afld linhge assembly lsee illustration)

~;=;:=~'7:::~~~

la' lhe,odislhreadedinlolheHlveras lhi. :=;::lhel>eighl 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 piv<>1 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"-anacci<:l,,nlisalmo.t

certaintooccurffthestandexlendswhilelhe machine is in motion. 8 For check and replacement or lhe . ide staod .wilch .... CMpIer8

5 H.ndleban.nd leveo; removal and installation

Handlebars Nota: If ntquir&d. the handleblJ~ c~n I>e 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
Levers Removal

~nd=i~~:~et~~:~~:o~ttt~v'! assem~y

(s"

Inustnltion) . If working on the

clutchlever,sIIpthacableendoutofthe~ver as~lswithdrawn.

8 To.emove Ihe lever blade Irom the pivo t assembly, unscrew the span adjuster pivot bolt locknut. then withdraw the bolt and removethe l8Y9t~ade (see i"ustnltlon5.7) .

Installation

9 Inslallalionis tha reverse 01 removal. Apply grease to the pivot boltshalts snd to the contact areas betwaen the lever and its brackel. Grease the clutch cableenc:l and fit it into the leve. before in st att ing th e leveGCted (see Chapter 1).

6 Forks removal and installation

Removal , Remove the front wheel (see Chapter 6). 2 Remove the front mudglU"d as des<: ri bed in Chapler 7.

7 To rernove th.e complete front brake iever or

3 Qn750models,unSCrew l heboHs$&euring tke brake hose cl amps and speedometer

clutch lever assembly from the master

Cllble guide to the lorka (see iIIu.slration)

5-6 Frame, suspension and final drive

8.3 Ho""gulde and cable guide bolt )arrowedi-750models

~ _

I

S/aCk e n;ngth 8 ,orkc/amp

bol,. /nlh9Iopyok9 befo", sl8ckenlng the forlr. fOp boll.

bolt. 71>/5 - : : :: :

~ ":.!7:/':

~..::.andheIP5

to p",servtl Ihe

5Notelheposllionoflhfllopotlhelork tubesr~alive t othetopyok eso thatthey8te

inslalJed in the same position (..... illustration 6.4). SlacklK\ bul do 001 remove the fork clamp bolts in lile bot1om yol<e, and remove the forks by twistlr>g Ihem and pu lling them downwards (..... illustration)

II.

SA Top yoke l orI< c"'mp bolt )alTowlld). Note the Blignmentofthe lorlc with the top yoke an aid to in. ...I... tion 8 1Ith.IOI1<s_.d i sasS&m~&d. inst a llt lle

4 Slacken. oot do not rernove forI<s are 10 be disassembled. II Is advisable 10 slackan tha fork top bolt' at this stage. Displaca l he hand labars if requ;red !or imprt>\l
Inst alla tion 8 Remove an lracas 01 corrosionffom lhe fOl1< tubes and Ihe yokn and slide the forks up throughthfl boIlom yol<e and the top yoke so thatlhey aligon w~h the lop yoke as r"Klt&d on

axIoInutlntothfl bonomo! Ihfl left-handfork ,see lllustratlonj .ooldonotllghtentlle(l)C1e nul clamp boll unl il the wh....t has t>een In5!all&dand IhfI IlXIe has beentighlen&d to tllecorrecllorque.lnstaWthfllrontrnudguard (...... Chapler 7) and tile front wheel (...... Chapl... 8).On750~ s.in slallt!>ebmk8 t>o""clampsonto lllelOl1<s andtightenlheir bolts """ure/y. 9 Checktheoperellonofthelronllor~and

:::.::;as belore laking the machine out onlhe

""""",al C_ lIlustration 6.4)

7 Tl{Ihten the!orI< cWnp bolls in the bonom yoke to the lorque selling Spe<:lfled at Ihe t>eginning of IheChapl", Isee illustration 6.5). Ht!>elorlc 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 fYSCfY
A

~~~~i:t:~!~::f:rk:~:~~

Unscrew thebolf Ifel)' c
this operation. 5 Slide ttle fork tube down inlO ttle slid&r end withdraw the spacer, spring seat and the spring from the lube, noling which way up theyfil (see illuslrations 7.26c, b and e) 6 Inver1thefork H3goveraswabiecontaiJ'l(lr andpumptheforkviOOrouslyloex~as

7.1 Frontforkcomponents I TOpboit 20-ting

6 Damper rod

3

4 Sptingseat

8 Reboundsptlng 9 Damperrodseat

5 Spring

lQ Forlr/vbe

s.-

7 Pislonting

accelerated rate 01 wear. Store all components in separate. ciearly·mar1led cootainers (se. illustration)

II Bottom bush 12 Dus/seal

16TOpbush 17ForlrsJider

13 Retammgclip

18S&aJingw3$h&r 19 Damperrodbolt

14 0;1_/

2Q OiIdrainSCfflw

2 Before disman tl ing Ihefor1l,ltisadvised that the damper rod bott be slackened at this stage. To access the !&fI-hand fork damper

much lorkoll as possible. 7 Remove Ihe slackened damper rod bolt arxl its copper sealing washer/rom the bottom of the slider . Discard the sealing washerasa new one must be used on reassembly. If the damper rod boll wasnol slackened before dismantling the/ork, ~maybenecessaryto re-Install the spring, spring seal. spacer and lop bolt to pravent the damper rod from turning. Alternat ively, a leng th of wooden doweling pressed hard into the damper rod head quite olten suffices. Nole: A damper rod holding tool can be {)(JfChased from Kawasaki dooIet5fseeStfJp20j 8 Invert Ihe fork and withdraw Ihe damper rod from inside the fork tUbe. Remove the rebound springlromthedamperrod (se. illustration) 9 Carelully prise OI.It the dust seal /romthe top of tl\e slider to gain ac<:ess to the 001 seal retaining clip (see iltustretlon). Discard the dusl seelasa J'I(IW one must be used 10 Garelu lfy remove !he retaining cl ip, taking care not toscra!ch the surface of the tube (se. illustratlon).

II

5- a Frame, suspension and final drive

11 TO""P"fllte thfl tubefromthe s li<;lerHwtII

~~~~~~~~

~~~~~~~­

benecessary t odi~thfl t opbushaoooil

seal. Thto bot1om bush should no! pass tNoughthfltOpbush.lV>dth is canbe~to

goodelfec!. Push the tube oently inwards unt il it stops against the dampet rod seat Take care oot to dO this lorcibly or thfl seat may be damaged. Then pul thfl tube sharply ovtwardsooliltne bottombush strikM thfl tOp bush. Repea! this operation un!il the top bush aoo seal are lapped out ofth...llder

I."

~~~~~o;~.. tube removed. slide 01' the oil ~~=:--,,--::-:--,-----:-:--: seafood

~s

wasl>ef. followed by the lop bush,

:~:~ ;;~:I t:;afi~~S:ol::S~:!lt~

.'"

CllulJon: Do 11<)1 remo ... II,. bottom bu.h from Ih .. lube unless;1 Is 1o be repIac&d. 13 Tlp the damper rod seat oot of thfl slider. no\i"llwllK:hwayup ittiU

Inspection 14 Clean all panstn solvenl and bklwtl>em

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 Checlaf oauge lsee ilklstnltion) . No

.ervice limit I, given by Kawasaki. but II ruoout I• •• cesslves&ektheadv;ce ofa Kawasaki deal« or auspension.pecialisl. Wllrning : If II Is b ..nt, II shou/d

A ,

nolbe.trelghl.nfl1;replllf:. lt

wlrh"".wone. III Cl>eck the SPflng tor cracks and ot her damage. Measure the spring free lenglh usi"ll a steel Me and compare thfl .................,enl 1o Ihe .pecillcatlons"t the beginning 01 the ~ter.HHisdetectiveorsaggedbelowthe servic
with

new ona. Never replace on/y onespting

Also d>eck the rebound spring 17 Examfne the worI
18 Check thfl damper rod and its piston riog for damag .. and wea, . and replac .. Ihem il """""S3I)'(see llluslrallon)

Reassembly III If removed . Install the pistor1ring intotl\e groove n thfl damper rod head. then slidelhe ,eOOUnd spring ontotherod (seel"ustratlonj. Insert the damper rod inlo the fori< lube and slide ~ ... to ptace SO that il Pl'Qlects IuI/y 110m thfl bottom 01 tl\etube. theo install the seat on the bottom of the dampe< rod (see illustration). 20 Oil thfl lorI< lUbe and bottom bush wlth the spec;fledfork ol' andloserttheassemblylotc> thealiderl_ IUustratlonj . F~~newcopper

..... Iing wa.h ... to the dampe' rod bol! and apply a lew drops of a suitabf. non_ permanent thread-Iockl"" compound. then

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. tempo
::"'!~i~e~.to ~~e~i:.::~e':t,': succeedslnholdingrlledamperrod.oblain 'heKawaS/lkls""'i<:6tooladapter(pl,no 5700r-t057) Indhandle (pI. (>0,57001.183)

21 Pu.hthe 1011< tube lu llyinto the siide< lhen 011 Ihe lop oosh and.lide it down ove< thatube(s. . ltIustratlon) .PreSSlheoosh squarely into~. , &celIS in the slider as lar as posslblll.theninsta~theoilsealwll5""' ( _

IIllIs tratlon).Eilher,,"e lhe ''''''ice tool(pl no 57001-1219) or a sultablllpiece 01 lubing

totap t hebushlully intopla~:the t ublng

musl be s lightly larger In diamete< than the

::~ ::e!~%~: ~a~",:~e<~~~ ~~ ~ !~et~t;e~~ t~~ t=~'::i:

pusl>ed 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 0<1 seal Smear the ..... l·slipswith lorkoilandsliOeK ove< the lUbe SO Ihat its mal1
23 Once Ihe seal Is corractly .eated,lit the retaining clip, making Sura II Is correclly Iocatedinitsgroove (_ iIIust ... tion). 24 Lubricalelhe lips ollhenewdu.tseal then slldeil Oown Ihe fori< lube and pre5$ rt into position (SH llluStrallon) 25 Sklwly pour in tha specilied quantily of lhe specified graOe of lorI< oIi and pump the

:~ ~~ ~~:;~~:d~~ ~-:!'!~:!:::~ Itdjuslment made by adding Of subtracting oil Fully compress the tol1< lube into the s iide< and measurelha lorI< 011 kI'J'" Irom Iha top of

tha tube (see IlluSlra UOn) . Add orsubtre<:1 forl overtighlen and damage lhem, Pullthatorl<

IS

5- 10 Frame, suspension and final drive

tllbe out 01 the slider as far as possible then install the spting with itscloser-WOtJfld coils at the top. followed by the spring seat and the spacer (see illllstrations) '1:7 Fit a new O-ring onto the fOf\( top bo~ il the old one Is In any way damaged or deteriorated. Thread the bolt Into the top 01 the fori< tube

A =J::?iE:F=

10 engage lhe threads of the top boItwffh the forl< lube. This is a potentially dangerous operallon and should be perfotmedwlth care, using an as sistant If nocessary-. Wipe off any ex"ess 011 before startinglopraventthepossJblNtyofsHpplng. 28 KoopthefOf\( tllbelullyu xtendedwhilst pressing on the spring. Screw the top bo lt carefully into the lork tube making sure it is not cross·threaded . NOle: The top bolt can be tightened to the specified torque selling at Ihis sl8ge If 1m, lube is held between tm, padded jaws of a vice, but do 00/ risk distorting the tube by doing so. A be tter methodis to tighten 1m, lop bolt when theforlc has boon instalJe<jin the bike and Is securely held In lhe bottom yo/<e 29 Install IhelOl'ks (see Section 6). •

Op T ~ I

8 Steering stemremovalandinstaliation

~~ =;~~~~~~:~~~~=~!

Removal t Remove the fuel tank (see Chapter 3) 2 Unscrew the bolts seculing thabrake hose uni(ln to the bottom yoke (see Illustration): the.-e Is 00 naed to disconnect the hydraulic

""~.

the steering stem (the adjuster ring has a collar which fi ts into the bearing cover. so they will probably come away together) (see Illustration), Push up on the bottom yoke to displace the O-ring 'rom between t he stem and the bearing. then remove the O·ring and discardi! asa new one must be usad (see Illustration). 9 Gently lower the bol1om yoke and steering stem OUI of the frame (see illustration 8.12a) 10 Remove theupperbeanngfromthe topof the steenng head (see illustration). Remove all l races of old greasafrom the bearings and races and check them for wear or damaga as

3 Remove the headlight and its bracket (see Chapter 8) 4 Remove the handlebars (see Section 5) 5 Ramove the instrument cluster (see Chapter 8) 6 Removethefronl fOl'ks (saeS&ction6) 7 Remove the steering stem bolt and washer (sealliustralion), liftthetopyokeoffthe steering stem

lower bearing from the sleering slem unless theysle 10 be replaced,

B.8b Displace the O-ring and dis<;ard it

8.10 Remove the upper bearing

~;:~~i~~!:s9;:~t~~~=:;,~~

Usearatc:het-typetoolwhen Installing the fork top bolt.

Thlsmakesitunnecessary-to

remove the tool from the boll whilst threading It In, thus making It flBsier to maintain a downward pr8SSUffIotIthesprlng.

8.8a Remove the locknut [A), ad)usterrlng (B) and the bearing cQver(C)

Frame, suspension and final drive 5- 11

I Rarmwlhellllr!ngllemi.... 5ection6). 2 R _ dtr..:: .. oIo1d gr.aselromthll ~1Irld'_..-.cIchecklhemlor_

~-. 3 Ther..::esahouldbepobhedandl,.. from Ind .... taHon •. lnsPKltheobear>ngrol ler1r lor IIgn. 01 w.ar. damage '" discoioraHon. and . xaml". lh.bearl"llr<)tt .... r. tainerc.ga l'" signs 0 1 ettteQ Of ep!il • . SP""the bearings by '-'d. They ahouIdapinlfMlyandsmoolhly. " I""', . r. any .Ignt 01 waar on any ollhe above COn1pon1(\lt both """'" and low... beIring~muslbeNJ)IaceCI lSa_.

OnIy_. lherac.. lIlheynooedtobe

::::*~~_~oncelhey"'''

Replacement

Installation II 5m&a<. liberil quantity 01 gr... seon the bearing r..:M1n the frame. Wen; grease willi into both the uPI* II>d Iow..- biNrings i_ llustration). 12 C.r.,ully lilt the . te..-lng lIemIbottom ,.,...."4'rtvoughlhelrtomt (_~lustrltionl InSI"lheupperbear~lnlhelopof l he

s le.lnghead,ll>enli1ther>ewO-tlng ( _ NI... tr. Uon 8.8b) . lnstIUthebelringcoYer 1fIdlllreadlhe.cllullerrlng.wlthllsstepped sidelac:irogdowrl.lIrldkld
remQvad . ylllh •• I_ingl.sblelo moV
the .terng 51... through ~ . lull lock 1M! Of slxt..... lllenr..::'"'-<; kl""raepl.y.Check

. ndadjul l'habaarlng . . . describad ln CllaptertartlrlnltanatlO41 l1 comp1eta. C.urion, Taka "ra" ca,.. nor 10 apply

... ce.sIW~A u .. bacaus.lhiswlllC8UH ~1"",/.lIurwoflha-.;"gs.

13 .... t.allhe lop)'Ok.ontolhllateerings' ...

4 TlMorac. . . . . aointerlerenc.fit in theo . t-w,g hal
IHI illustration). 1... lall theo SlaMIng 51...

bohllrldllswashlrllrldtigltlenitlingoer·tigltl only al U·II • •lage (HI lIIuslralion

8.11.

TIrI1POfIriI\tInstall_oItheforUtoalignlhe lop and bollom yoIc ... Ind "",ura it by

tigNeringthebottomyokld.npboh.odt 14 theo . I....,ng . lam bon 10 lhe specifiad tOfQUlMttir!g i_Wlu. lrlItlon) 15 In1ta11ttlalronlforU i_Saction6) 16 Ins'all Ih. r..... lnlnQ com"""""t. and Inemblles In a r eV
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 b
2 ThkJrwas/w 3 Gc"de1orJowlJr,."

diameter

HCOnd sI>odc i. ,_ed. but "so making ....... thallhe~oIlh1rnactoin11isotflhe rearsuspenslonsoth.,thl ,ho<: ksar.. not =:~!e,::;,.,~ternltr,.ejy ,remoll'onlyone

beatingandoo..notcontKttl>l'~ ,Of

betterllilllj•• washerbeTw""tl>lbNrlr>g

2 On 550 modejl, .. mo .... the .~haust ,y.",m. and on 1SO model •• remove tile lil
_lhetubinglOprotectlhe~

rarnovedlrom~boItIlIIn<:Irs~boIh

8 tnstaIlhe

I Pr..-II-.,-races Into u..1..-1 UIing. dJawboIt . .angement 1_ .....UllIIonI,Otby utIng . '..ged'ametl
,n

-,-w.u . 'em IsM Section t!I.

10 Re.. lhockabaorbers· removal,inspectionand

ioSCaliation Remollal

~rw::r"~n~,hltI:;Ulbo~~ ~~:.:~t!

-

Hlhlbanlglt~lnplac:o&~

wilCI~IO.-.banlgllUl*.Ofin

.xtr..... c;ircumstances 10 split tftl bearing'. InnItsection 1_IIt",UlllIonl.

,.4

Orivethenewbearlngonl>llrlg. 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. .. Supporlingthlthockablorbl<,unscrew and ,1I'I'IOVfI the uppar rnountlng boll and w....... trw. r......:tWI the Ihock ISH

7 70 remo .... the lower be.tlng Irom the , ttaring lIem. clamp tlle.tem In • vic. and .... lWOft.I ·_~.pl8Cedon oppoti"~oIth1r_toworlchfr... Ulingblocl
~~,-=,I::=er,!..

~~ ~;:::~:::Tu~t~~S

10.... UnscrawtheUWl
Frame, suspension and final drive 5- 13

10.10 Make sure the chain guard brac ket is corre<:tlyaligned

Inspection

Installation

5 Inspect the shock absorber lo r obvious physlcat damage and the coli spring lor looseness. cracks Ol signs 01 laHgoo 6 Inspect Ihe damper rod lor signs of bending. pilling and oil leakage (see illustration) . 7 Inspect the pivot hardware at the l op aoo bottom 01 the shock lor wear Ol damage (see iIlustrallon). 8 If Ihe shock absorber Is In any way damaged Or worn il must be rep laced Individual rep lacement components are not available 9 Kawasaki specify releasing the nit rogen gas pressure befo re disca rding Ihe shock absorber. To do this. r&mOve Ihe cap from the base of Ihe reservoir, then, using a s.<:rewdriver Ol other suitable too. depress the valve until all the nitrogen is released. If In doubl,taka the shocka to a dealer lor disposal Warning: Do not point the valve lowardsyou when releasing Ihe nitrogen-it /s underoonsJderabie pre$$u""andanollmlslwHl also

10 Installation Is the reverse o f removal. noting the following. a) Apply multi-purpose lithium grease to the pivotpoinl$ b) Ins l8lllheuppermountingboitfir.st, but

.

_-

'!'::st ~~:~it

until th8 /ower mounting

c)/fthechainguardhasbeet1removed, mal<e sure the chain guardbracket is COf7VCtiy posWonoo (see illustratkm). d} T/flhtenthe Iowarmountlngboit(lelt·fland sjdfl) and nul (righl-I!and sjde} 10 the ICtqUfl setb"ng speclflfldat the beginning 01 tfle Chaptar. a) Adjust the suspension as required (see Section!t). fjChacktheoparationofth8suspen!ion befora taking th8 mechine on the road.

11 Rear shock absorbers -

adjustment

settings wi//uput the handling ollhe m achine and cou/d cause II 10 b ecome

Spring pre-load t Pre-load adjustment Is made using a suitable slim bar (one of Ihe Ph illips scrawdriversprovided in the toolkil will do) Insarted Into one of the holes in the pra-load adjustar ring on the boUom (550 models) or top (750 modals) of the shock {see illustrations). The<e are five positions, each Indicated bya s!apin the adjuster ring :~~~e step required with Ihe adjustment 2 0n550models.to increasathept"e-load , turn the spring seat anli -ciockw ise{towards the Iront of the bike). To deo;: rease tha preIoad. t umthespringseatclockwisa.Pos~ion

2 is the standard sening fOl a rider 01 average buiid.fidingsolo

~ ~u~nt:~;i~e~~·a~oc:~~e:i~~ t(~::;~~o~hd~ ~

CButlon: AlwBYS ensure that both shoc/C absorber se ttings Bre the same. Uneven

front 01 the bike). To deo;:rease the pre·load. tum the spring seat an!i-(:Iockwisa. i>osition 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-.."andat
Rebound da mping ll RebcIosod~lodjuItmenllsmadtb)l

turning 1headjusler on lne bol1om of the .noekebsorber l_w .... trationj .n.er. ... klurpotltiont.dIonoIedb)lRoma-lnum.all. ='ltlhed..,...mng,positionllt'lhe

. ..,.

4 Unhook tne lower enct 01 the t>raQ light lwi1ch.pnng...cfposiliontl>esptingoutol 5 Suppoo1ing lhel.,..;"ga,m.f8fIlO¥'IIlhe.Ihock IbsorI>tor 10_ mounlinv bollll 4_ s.<;tlon 10). Allo """,,,va chainvua,d ~ ,eq.Jiredl_Chapti:l<7j II Balor. removing the swinQ"m It I, acMIabIelOfI...:I>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~

I
I On 5SOmod"'. """".. the alrack.tlrld lorljUaarrnassamblyto tha t il _ . not impede ,emoval of t"" Iwlngllm, mlklr>g SI.l<' !hat"" sltain Is placedontM'-t.

12.7c ... endwithdntwthapivo!boIt

Frame. suspension and final drive 5- 15 O)LOOPIhI""",,,~"""'rhlsMngann

a/tlsolftN.s""lolhI_ f _

--

IlluttntlonJ._~_IhI~

s61der1s~101he~1ItId_

II'YCralrtwlltldlhin,*-_CI:ImIdIy

cJ1Jghltnlhl~pNot_llCIrlOlhI

~MlIWI9spedliedlllhe~~

otIheChlpMo-r-HiUSITIlionJ. dJ11QhttnlhlOrBM/DIflUIlI"mllClllorllt ~lOIq<MsMtmg.

"J1lg/>ttnIheIhocJ
12.8 Replacllhtcl\aI" . IIde
f)ClIICklhe~lioIlofrhefNf

~Oefontlelling l"'m«hinfIOf1

a inIptc1a1iC
Insf all.tlon

to 1n.,.IIll,ioIIIa lht ..... trHol '_ a l . noUIglhtlololWlg. -'RIImoI'trn.gr-."IromIlllCll~

Mdwilhchwrn. ..... _1rom1hl

~rr.....\ltIticIIrern.~_

13 Swingarm - inSpection and bearing replacement

~workcommeno:;.es _Thef\8W beat1ng.

l ThOfough1yclNnalicomponentt.~ "t"-oIdin._~·

:::=-~":.:=~:~rI

rhelhoclrlb.sOft>eorpivorbo/lshatli<switll

" R8I'I'IOWIlhegrease&eailromuchbelring and wltlld,aw t he in .... ' sl ....... f,om thl Iwlnga,m (... lIIus tra llona). lnspect th"m arid the bNtngs lor s!gnsol_or n.mag. IItId replaca them 11 .-sary 5 WOfflDunng.canbed'iftedOlltofth~r bor... but note Ihal ".nlO.al wiMdftt,DY them; f\8W bearirlgs should be oblallled

IPflIY plenty 01 molybdenum dis\llphide 1I'_ 1_ .....tonlonl

Inspection :! inl!»CtMccwnponentsclosely.lookingfor otMoutllignsof_suchll5heavyscoring. and e'ec:kl or dlslOl1ion due 10 \lCCld8f\1 damagl. Anyd.maged or worn compon&nt

~dosulpNde~_

ortht~.tJ
Se.ring replacement

~ =~~=8f\or!:w;,~Iof\~F:= belringswilhthtmar1
~c:fsut;rhidegraser-

~.AbQ~ltI!Jpivolbo/l:lItId

3 C~k II>t .w~rm pivot boll tor lrr.lghtlllMbyrt*lg~Of1"l\alsurf_1UCII

. . . ~oIpIa\lgIass(/rllwiptoflalioid ",_II'ld""""'.nyCClm>liOfluaingllne ....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.mII
UIIICI_lhe bolls securing lhe engiM 1IjlrOd<1I_loIhltCfllllk<:asa_ ......... I h e _ ,_illusIratlons14.2b_el 2 (),..;Itrhe_pan"",onbothsprocl
epn:>Ck" •••• S81. Whenftv ... the SptOCket. ,,.Inspecled.thl d rl",chai"Ihouldbe Inlpected llao(IH Chapt ... ,). II yoo ar.

14.2~EII9I ... ~ k lICO\l erbolts ( . rrow~

_150 models Ilnoma.l
14 Drive chain - remov~. cleaningardinst~latioo

'emovInQlhearm"'lhat~can""_tly

~ =.~:::.:.taIIa~r:-co:

Re mOIf. 1

::,;:~~===~m:

t8q<1ite1 /lie removal of /lie $WiIlgasm . .

detailed below. 0< If /111 necessary chain brIIIdngendjoiningrooli$_.IhI<;hein c.'Iblwpartlred_refoiI*:1(ueTooI3_ Worlrshopnp. .... rI!eRe'-'<:ewclkrtl). Werning: NEVER In' ll'lI e drlVl I ch.ln which us .... cUp·fype • ",..ler{opUf)fit1k. j ~ ... lhllwing.arm{_SectIon12) 2 lJn1a1wlhe\lNlc\larlgl>linkagearmpinch 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.
3 PIIoc.1he mechinfl

II4lPO'1

Ihree~MCUringlhefrontsprocl<eto;:n.rn

~mounledegainallheovtlicMoIIIII

gukIe_ ......... lheguk!e (........ It1IIion,I.

IP'ocI<eT MI
~-;-,.:-:.~':--I.ontaproc;kll.nd C/•• ning 4 Soalt!he ch.ln In paraffin (l<erowne) 10< 1IIPP"II~"""'eIy""'O<""",""",H.

C.ul/on:Don 'f .... rI'IsoIine(petrol}, _ _ ~ cllen/ng fluid•• ..,. h!gh-prfluurfl w.I ..... R_/llechl/n, ....... ltoff.thenblo ... '*Y II wllh comptWssed elr Immedial.ly. 1he .nflrlptOCl>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!aoelhesproclCl<et, 5 Adju"_lubr\cal"httdlain loIowIng till procedures delc:ribedin Chept ... 1. ==~ U. . only /h . recomm.nded

Frame, suspension and final drive 5 e 17

Replacement Front sproc ket

:.,~n::;':::'~I~O~I~!::~ ooling any alignmenl mal1
Un screw the bolts securing t he engine sprocket cov. to the crankcase and """"ve tlll!~ l setl iliustrationI4.2b8l"ldcl

the gearchange IInkage arm onto the thah and shift the tmnsmiss;on into gear. then

7

IllSt a ~

=e~:~~~t::~~=::

10 Siidetl>esprocl<etand chaWloff the 'Ih
those In t he sprocket l see Illu stralion sl Inslall t he sprockelboltsand , u. ing the methodempioy«l on ramovalloprevenl the tmnsmissionfTornluming.t;gtrtenlhem tolhe 100'1ue selling spec ilied at lhe beginning of theChapte«s ... ill .... trallon). 13 On 7 SO m~I •• lnstali thesprocket n... t w ith its lockwaSher and , using Ihemethod employed on removal 10 p!"event t he transmission from lurning. tighlen it to the Io
the Chapt&r . Sendup the ta bsonthe Ioc kwasher t o s&cu,e the nul In" Illustration).

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

&nabI8you l oslackenand remove theeongine

sprockeibotlso
8 00 550 model s ....nScrew the bolts. then tum the sproci<et plare slightly entklockwise unl il the splln&$Wl l lII! plate alignwith t llo6e on the shall and removelhe plate Is-" ~ t .... trallon) 9 On 750 modelS. bend back the tab on the sp!"ockel nul Iockwasher, then Unscrew Ihe sprocket nul and ,emOve it with the lockwash&r. Ch&Ck Ihe cond illon 01 'he lockwasher and renew il if weakened Or

5

15. 13 ae:':::=:::st>ertab

5- 18 Frame, suspension and final drive

Rear aprocket 15 F\en1ovo1 lherearwheellseeChapt... 6). Ie UnscrIW lhenutSHCuri"" thesprock"t to the whHl couptlr>g. 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
...-.d(llnlfaldlterioralion laeeillust.-1lon)

.......,

A~ l he"'_dampets lI ' IHIII

1&.3

" i;"'~U:=.,.,MQmMI"

I CheckirIg.-.d~tprocedlnlfor

-.

11M aprucI<eI COUpling bearing •• desCritMd

~=u!ilthI_oI....-.I.MakI IU,' the space< iaCOfr&ctly inSlal1ed 10 the

fllnllaDlhe"-_lseeChapt ... fI).

6·' Chapter 6 Brakes, wheels and tyres Contents Brake fluid!evel- chec:k . . . ...... . ......... Oaily(l:w".... r'
Brak" light switches - cneck and rep""""""'!

........ Chapter 1\

Brakepads - W
. .&eeChaplert

Rearbfakecaliper -,emovoa , lMIrhaul and installalion

7

Rearbrak"d;sc -ins!*'lion. """""aland lnstal/atlon Rearbtak.. """,terC)llirder - l'fImOVal,overhIIoIandlnstalation

8 9

=~=~~:=~llM;;;'·:...

....... ..... 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
3 4

==:~=al, ..,opectlonand in$la11alion .. ~~.~.P.l~~

Front brake ma,uft'cylioder - removal,ovMl1au1 and installation

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:
..

Rad/a1!OOI·Qf·round).

~=~,~.~rear) SwvIc:e ~mi' ..

0.5mm

0.8mm 16SS1hM0.05mm 0.2mm

•

6-2 Brakes, wheels and tyres Tyres Tyrepressuresandtteaddepth Tyresizes-5SOmodeis Front •.. 110180 ·17 Rear .. 140/70 · 18 Tyre sizes-750models Front. 120170·17 Rear... ... . .. . . .. . . . ..... . . . . . .......... .. .. . . ... ...... 150170 - 17 'Referto the owners handbook, the lyre informelion label, orllKllwllSlllddelllerforfllJPfOvedlyrebrands/lfldspeedf/lfing.

Torque settings FrootbrakftCIIllpermountingbolts 55DmodeIs. 7SOmodeis .....•..•......•..•... Front brake master cylinder clamp bolts 550 models . 7SOmodeis .......... Brake hose banjo bolls ..

32Nm 34Nm 11 Nm

___

aM 8.8Nm 25Nm

Rear brake CIIliperrT\OU1tingbolts 55Omode!s . .. ..... . ......... . ... . .. • •.. 7SOmodeis ........• 6/"iIketorquearmnuts 55Omod~s ............ .. .. .. . . . . . . ... . . 150models ... .

Rear bo"ake master cylinder boIt$

23Nm 68Nm

Frontaxle .. . .. ..... ....... . . ..... .... . . . Frontaxieelampbolt$ 550models .. Reilre~le nut ..... . ....•...•. Chainadjusterclampbolts ..

Slide the caliper in on its sIidefs unt~ Ihe Inner

1 General infonnation

All rnode!s coverfld in th iS mMual are fined wlltl cast alloy wtl&els, except tile ZR750 0 mod~.wtlich hasSpok&dwtlHls. Tubeless tyres are uSl)d on the cast wheels, and tubed \yres on spokfld wheels. Bolh front and rear brakes are hydrauHcal1y operatfld disc brakes. On 550 models. the front tlas dual sliding calipers with twi n pistons, ttl e rear on 61, 62 and 63 models has a single sliding caliper with twin pistons, and ttle rear on 64, B5and B6mode1s has a single sliding caliper with singla piston. On 750 models. ttlefront has dual sliding Cllilpers with twin pistons. and the rear has a sirlgle slidlngcaliper withtwln pistons Caution: Disc bralre compon""ts ntre!y ,..qui,. disasa.mb!y. Do not dlslIssemblll components unless absolutely necessary. IllI hydraulic brak_ line is loosened, the entire $y$:tem mu$! M disassembled, drained, cleaned Bnd then properly filled end bled upon reBssembly. Do not use

2 Front brake pads replacement

+Lll.

~ ::"~bet!c~~:~:~.~$Oca~= ~

:::u::.

pad spring Is titled and remove It it

~:':~:e ~~t:;;,s~~~~-:'a~~ ~a~;"Z:~t~ =:~~u~:;~~e ~~:.a~~

BSM.tOS, which I. harmful to your heBlth. Never blow it out with compressed air Bnd don't inhale any of It. An approved filtering maslllhouid be wom when wOf1(ing on the brakes. 1 On an except ZR750 0 models. lJI'I$CfeW the brake caliper mounting bolts and slide tile caliper off the disc (see iIIustrallon 3.2al Remove the outet pad from the caliper body, noting how the proln.JSK>n on each end of the padlocatesag~n$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 repla<:eduasel ('Hllluetration) .llyooateindoubtllbout the emountol I~ct ion meterlalleft, measure the thickness 01 the material. II ~ is 1 mm Of ~ ,thepad . mu.lbflrepiaced.NoIelhal~

IS rIOt pos.lble to degrea"" the Irlcllon materi8l:ilthepadslll'econtaminatedinany waytheymust bflr&pillced. • If the pads ate in good conditton clean them c arefully. using aline wir& bru!lh which is ~lreeolcNtar.dgrea""toremolle1lll

tr_, ofroaddil'1andcofTO!ion.Usln\l8 poonted IMlrument, dean out the \lrooves in thelricttonmateri8landdigOV1I1J1'r"/errt>edded partie "'. olloreign matter. Any ftre as 01 glalingmayberemovedu*'!Iernerydolh 5 Che<:kthebrakedisccondition(Sec1ioro4). 6 On ZR750 0 models . ........,ve a ~ Irac:H of CO!TOISion Irom the pad pin. Inspecl the pin lor oignsold"""'ll"lIndrep/a(:
as pos .. ble us ing haoo preSSUfeonfy(see l.... stnotlon7.11).Duetothe ......easlldlrlcliorl materiaj thickness of new peds. ~ may be n"<"'''''~ to remove the muter cyfinder reservorrOO'lfJllanddiaptvagmardslphonOV1 someflUd.

B $mearthebacksolthepadsandthe_nk 01 the pad pin (ZR750 0 models onlyl wrth oopper-based grease. making sure II"1II1 none gel. on the Iron! QII . k:Ift 01 the pam 9 On a! e.ceptZR750Dmode!s .imtallatiorl 01 the pads is Ihe ."ver"" 01 removal, Make SU'eUlepadspringandguiOesatlcorrectly posotioned(see i"ustratlon). Insert the pads Into the caliper SO Ihat the IrIctton material 01 each pad will t>& lacing the disc , Milke Sure the protruslonon each end 01 the outer pad locates C
11 tnst8 11the ca liper on tt>e brake disc making SlJre tha pad. sit sqUllrelyeilher_ 01 the disc (_I .... SlOlIlon3.13). 12 Insta ll the calipe< mounUng bolts. and to the torque setting apecifl8d at the begLolning 01 th;,; C/!aflter (see H1u.tratlon 3.1') 13 Top u~ the master cylinder reseMlit il necessary(se"Daily(pre-ride)ehecb),and

.""them

~=he r"""rvoircover anddi,pI"I~1I

14 Operate the brake lever s_al times to bring theplds into contact with the disc. Checkllle~tarcylinderfluidtevel("""Dei1y

(pre-nde) checks) and tile operation 01 the brllke beloreriding themotorcyc/e.

Removal

Rerr\ovethe

""'*'

1 bnlke hose bolt. noting its posotoon on the o;.al;per and saparata the hose lromthecl llper(seel!lustratlon), Piuglhe hoeeeodO<'wr".:laplasti<:bagt"1lllYaroo.n:l~
youareovert>aU01grt>eca/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$connectlfleho$lJO<>Celile 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<-akH. 00 not, under any errc;umsl.nces, use petrole um-besed soA>. nt, tc>clean br. ke p.rts. Useelean br/Jkefluld,br.ke cleenerorden.ture<1 .kohoIonIy.

...,--.,."..r-o_

3.t

~t8thebrake hoseali9nmentl>elore

unacrewlngthebanioboh(aml_dl

Co.:rectIyPOsi t ~,lnsertthepadSlntothe

CIIIopersotMiIhetr'ctionmaterialolMdlpad wllbeladnglhe(!jsc_MakeSll'etheprotn.lSlon on tile outer pad IocatH correctiy against the guide. Make SlJrethe pad pin passes ltIrough Mdlpad.rodSIIC\H~withIheR·pin .

3.2a

Brak~caHpermountJngbolts

(alTa-!)

3.2b Aemovethe insu/atorpiece lrom 8achpis ton

6- 4 Brakes, wheels and tyres

3.38 Front brlIke caliper ComponentS - (til models • • cept ZR750 0 1 Brakepads

2 Pklspt1ng 3 Oulerpedgu!des

"... 5 Pi5ton

Overhaul 3 Clean the ."tenor 01 the caliper with

denatured ak:ohol Of brak. Iyltem cleaner

1_lIIustntlonsl, 4 Remove the pl$tons from lhec:alipflr body, eitherbypumpingthemoutbyoperamglhe frontbrak. lever until lhe pistons ar. displaced, or by IOfClng them out using c:omprltlMdalr. Not. theton all.xcept750 Dl models, IWO sizes ot piston areused,and Itlst dilterent Ilze _Is are used ac:c:ordingfy. MIWk each piston lINd and caliper body with alellmarllerto .......... tnatlhepistonsc:anbe matched 10 th.'r original bores on reas&embly.llt1\tlc:ompressedalrmelhodis used, piece. wad 01 rag bel-..Ihe pistons and lhec:aliperIO.ct asaCU$hiOn,1hen use c:ompressed ... (tIrected lniolhefluid Inlet 10

forc:elhepislon.out o'ihebody. Use only low PfHlUf.10 eas. the pistons out and

make sur. bolhplllont_dlsplacedat Ihe same lime. 11 the alr pressur' Ie too high and Ihepislonaar.forcedout.lhecaliperandlOf pistons may be damaged.

& =;';:~:::t~f?=;£E ~whenapply/tlf/c:ompf"tSHd

air, .. -'ocnlfl}uryc:ouklrNult. 5 I.1$ingawoooenOfplestk:tooI,removelhe duslsealsfromthec:aliperboresanddisc:ard them lne ltlutlratJon). Nawsealsl"I'IU$tbe usedonlnstan.tlon . llamelallool is belflf/ used. lak. gfHt cafe not to damag. the ealiperbores.

6 DuslS4HJI 7 Pi5tonS4HJI 8B1etJdvalve 9S1iOerpinboor

,--

3.3b Front brlIk. eallper componenta - ZR750 0 modell 7 Pedspring

2 Pklpin

8SJiderpin bool

3 R-pin

9 Ourerpedguide 10 BIHd v. . .

-..,.

e~and~lhepislonsealsin the

7 Cleanthepistonland bores with denal1..red alcohol , clean brake nuid or brak. Iystem aear-. n compressed ... is available, use h tooryth.parta thOfoughfy(mak.sure II'a filteredandlriJbric:aIed). Caution: N. v. r " " a J>if'l"Olallm-ba. .d .oMtnllo clNn bnk. perfs. 8 InlptCtthecallpe
Chec:k thai

thecaliparbodylaablatoslidalfealyonthe mcu'I\WIg~tsllderpns.l1sat1:addl.lalO

corroaIon,sapsraiethatwoc:omponantland daanoffaltr.oeao!toml$ionandhardenad grease. Apply I wnaarotc:opparOf IIIIk:onebeH'df/reasetothamountingbrackttsIiOtr pinsandreassamblalhetwo~ (_

Illustnitlonj.Raplacalherubbarboolsifthey

•• t:llrmlgadotdateriotated l_llluatl'atlonl. tlthecsliperisinbadshapathefl\lSter cyhtwlhooJdlllsobeo;hackad. II L.ubric:at. the new plstonsaals wilhclesn brakt~andmtalthaminthalrflJOO\'tl ln

Brakes, wheels and tyres 6a5

Ihtocaliptlrbotes.Notelhalonallexce pl

Tlghlen 11M banjo boll 10 Ihe lorque sailing

ZR7500mode!s.!WQmesoibore andp/$lon

~11':h: ~':~i:"',!~ft~h~h:':';"um

::::1h..~~heca!r':s:~~;:!: ;~'::~ Ihecorre¢1 bores. The same applies ... hen

~~~u!,:=g;:~:1~~or:ilh

clNn tnkefluid and ooallthem in their grooves in 1I>e 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 ehosesothatitfitslnto

its slot io Ih&caliper (see IlIu . tration 3.11.

4

~=~~~j:a,i~~kl!1, ~

'"

gauge 10 e fori< leg, ... ~h lhe plunger on Ih' gauge toocNog the surface 01 the disc about 10 mm (112 inch) from lhe Dg with the lin"Iit isted Itt the Specifocationsal lhebeglroWlg oItheChapt .... lttherunout is~... thanthe !l&fYice1m~.ehecklhl _~lor pllly

(s" Chapler I ). H Ih"

bearings ara worn, replace them ($&ellon 16) and repeal this

cIleck.

Htheo:tiscrunoutis.titlexcessiw,~wiI

h..... e 10 be replsced,allhougi"lnw::lWW"lg by S

~~~~~be~

brakeoperation,botdeep gl"OO\l&!land heavy

towea,o:Iown to a thickness lesa thao the "Me, I ;m~ as listed in this Chapt..·s Speclficallons and as marl<ed on lhe o:Ilsc RseIf (seei"uetrationj. The thidoess oithe disc Can becheckedwilh a micromet... ISM M1Ultrationj. Klhethicknesaofthedisc is less lhanlheseMctllimit.HIrOstbereptaced.

scoremarks wiftr&ducebraldnge!ficiencyand """",,"te padweer.liso:liscisbelJy{;'"OClY"d Kn1\J$lbell"ll'Clineciorreplaceo:t.

.F'lemoveth,wheeI(SMSactk>rtl . )

Inspection

1 Visualiyinsp&ct1l>esurface oi theo:llscfOf score marks and Plh@< damage. Light IICRicl>es ar8 nonnalalt ... useandWl.>"l1.th,ct

2

Tocllecko:liscrunout.positionthebikeOl1~s

~Orel~::~'~i::::": grourld . Tum lhe harldlebars SO 1hallhe stHring is on lull lock either way. Moo..olI a dial

RefJtO".1

~:::'::';.,":n~o:"l~:;.t~~::' :o;;~ bftcoma warped. Set the wh_

on wood

bloclt.soth&dl.cdoeSll'tIlJpporflh& waightolthawheel.

8

•. 3.0 Themlnimumo:llSCthlcknassis marl<e-don thedisc

6-6 Brakes, wheels and lyres

5 Mar!<. the r&lalloolhlp of the diS(; to tke wheel. so it can be Installed in the sama position. UnS(;rew the disc retaining bolts. loosening Ihem a lillie at a time in a crisscrosspallemtoavolddlstortlngthad;sc.than remove the disc from the wheel (lea Illustratlonl .

Ins tallation 6 Install the disc on Ike wheel. aligning tke previously appl ied matchmarlls (if you'ra reinstalling tke original disc). Tt>e arrow matl<edonthtodlscmustbeontkeoutsida and point in tile ditactlon of normal wheel rotation t_llluslnltion 9A). 7 1nstllllilhediscbo/!sandtlght8l1thernina criss-cro,spaltamevanlyand prograssively 10 Ihatorque le1ling lpecified at Ike baginningofthtoChapter.Cleanoffangreasa lrornthebraked lsc(sjuslngacetoneorbrake sj'Stemcleanar. Uall8wbrskedlschasbearl installed.~anyprotactivecoatingffom ~s

working aurlacae .

9 Install thtolront wtIeeI (seeSaction 14). 9 Operate the brake 1 _ several tlm&S to bring the padllnto contact with the disc. Chack tha operation of the brakescarelully before rkling the bike.

5

Frontbrakemastercylinder -

~

r=lra~~verhaUI and

~

1 "lhemasll1fcytindar is leaking fluid. or if Iha lev.. doH not pnxIUCfI a firm feal when 1he braka Is applied. and bleeding the bmk. Ooesnothelp(saeS8ction 11). and ttIe hydraulic hose5 are din good condition. then mastllf cylinder ovllfhaul is recommended :1: Beforadillas.sembiingthemastercylindar. re.adthrOlightheentireprocedureandmaka lura that you hava the correct rebuild kit AI$O, you wilt nlHld $Oma new, clean brake fluid of the recommended type. some clean rags and lntarnal clrcllppliers. Nola: To

prevam dam/1f/8 10 fhe palm from splfl«! brakalluid. always cover tile fufi lank wher! worldfJr.

Caution: Dlsassambly, ovarhaul and , aanamblyoflhe brakemaslercyllnder must ba dona In a spotlassly claan wonr araa to avoid contamination andposslbla fallura 01 Ilia braka hydraulic systam

-'. Removal

3 Ramove the ..- view mirTo, (Chapt. 7). .. loosen, but do not rernov.. tha seraw. ho!dinglhereservolrcoverlnplaca l lee

hluatntloo). SDisconll8Clthe&lectricalconnact~ from thatnkelightswitch (sae~lu!tratlon) .

IS Ramove the Iront brake lever (Chapter 5). 7 Pull back the rubber cover on the brake hosa banjo botl,then unsc,ew lha bolt and separate lha hose from the mastercylindar, JlQIlng ita alignment (saa lIIustrallon). Discard the two saaling washers as thay must be

5.7 Peel back the rubbarboot toaxpose the bntkahoN banjo bolt. Nota the .~gnment of the hose

Brakes. wheels and tyres 6- 7

5.8 Front brake master cylinder clamp bolts (arrowed)

new 0I"Ie$. Wrap ~ne end of ~he hose in a clean rag and suspend j~ in a n upr\ghtpositlonorbend ildowncarefullyand place the open endirt a deen coruainer. The obje<:live is 10 prevenI exces_1oss of brake replllC$d "';!h

MuId.!Ii..Odsplllsandsystemeontamination

' - - - ---:-:--::-,,--:--,-----::-c-----:---------'

8 Unscrew tha mut'" cylinder clamp boIIe. ~hen I ~t the master cylinder and reservol' BWayfromthehand_.not>nghowlhatop mating surfaces 0 1 the clamp a lig n with tile top mating . urface!I 01 ~h e . wilch hOlJsjng

5.' Front brake masttor eyIInder componentS fFIIJbWboor 2 Brakehosebl/ftiOboI!

!~sh«a

(... IIkn1lrat1onj.

Caution: Do not tip the m . . te, cylinder uPside down OI"braka fluid wNlnm ouf.

Overhaul 9RlInIOYethe , eservoircover relainingscrews and lift off the cover. the (hpIYagm plal.ancI the rubberdiaplw"agmI_Mlus1nltionj.Drain ~he btaJce flui<:! from the ' nervoi, inlo •

16 Instal l the spring inlhe masl ... cylinder end flrst so that ~.taperedend taces the piston. 17 Lubricate the compo
w~h ~swider

"

RvbbeIdvUboor

9Citc1ip

'OPiaUJn~&Spring

11 Bnlkelighrswirch

Make sure tile lips on tile cup seafs do not IlImlnskleoutwhen lheylnstippedintolM bore. Depress the p;s~on and install the new circiip. ensuring it locates In the masl", cylindergroove(_~ l uelnllIon).

18 Insulltile rubber dU$Iboot. making s .... Ihelipisseatedcorrectl)'",lhepls~onl7~

su~abl e cont8iner.Wipelll1yremainingfluid

01 the 'eservoir wittl a cIeIIn reg 10 Unscrewthescrew securing the brakelight switoh tothebotlomoflhemasl... cylinderand removetheswilchl_llustratlon) 11 Caretull)' remove Ihe dusl boot from ~ha end olthepislon(_l lIustraUonj. 12 Usingcirclipp'ers.'......,.,.."hecirclipand slide CUI ~ he piston assembly and the spr'ng. notingl>owlhaym(.... 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. cylin
the pad spring is fitted and remove n required.

~ ~he~~~::::1ngB6~ =: ~

:~;~~~ ;;~~~;:r:::,,!:

your II""ltll, N"~~r blow It out wi!I>com",-ssed"/r"nddon't /nl>"IfI,,ny oflt,AnlJPlU'OVfKlfl,**,gmulrshould be womwlMnW<>l1 .. bnlkes, 1 On ZR550 81, 82 and 83 and all 750 II'IQ(!els,unscrewlhebral<ecaliperrnountlng boilS and slid .. Ihe Callpef 011 thedl 5<: (s .. e Illuslratlon7.2b), F\emovethe ootlll' padlrom the caliper body,ooling how lhe pro!r\lSion on each end 01 100 pad locales &ga",,1 lheguide (SM 1I1uslt"llon2.ta). Slide thecaJiper in on ~s sliOer'1I ""III the inOlf pad can be lilted off ~sguidepins on the caliper mounting bracket (see illusltation 2.tb), Also lake ooteol how

caliper off the disc (.... IlIuslrallon7.2a). Remove lIMo R'pOn!rom Ihe end of lhe pad .e/ainingpin, lhenwilh(lrawlh
=~~~=)~.:~~~wr:~ innerpad, ootngwhichwwyroundrtfrts.

~0~1=~1I:~ a:rI~r!c~f th:~C~he~~ti~ material has flQt worn beyond rts service I mrt ~ ~her pad is worn down 10, or beyond, the servicelim~_st8!l,lioeorll'''''''''("''' they arefIQloogervi"bIe), j ouledwith~Of Il'_,

Q. heavily 5<:or8
22 Connecl the b.ake hQ"" tQ the master cylinder,u";ngnewsealingwMhersOfleach side QI the unlQn, and alij;jnlng t he hose as rIOted on removal (se .. Illu st.ation 5.7). nghlen the banjo boll tolhe to.q L>e .enlng specified at too b6giming of this Chapt'" 23 Insta!l too brake /oMlf (see Chapte< 5) 24 Fill the lIu id reservoir 10 Ihe ma~imum level line with lhespeciliedb.ak .. I'uid (.... IIlu. t.ation) . Aele. 10 SecIOon 11 of th is ChaptM ane/bIeed tooa~lromt h
coverOfltolhemasteow its prolnJslons (arrowed) locate

Brakes, wheels and tyres 6-9 Rem oval 1 Removelhebrakel>o5ebanjo~t,notir>g

itspo.ilion on the cali per and separale the hose lrorn the caliper loee Illustration). Plug the hoseeod or wrap a plaslic bag lightly aroond ~to min imiselluid Ie." and prevent

~~s::~': I::::":,~,:. ~~~~~sS:li~ Installation . Note: Ifyoo are planning 10 ovettIauIlhecaJ~enddor!lhaWJs$Ol.HCe ot~airloblowourlhepl$rons.jus l Ioosenlhebanjobolra r

6.10. Ma"'sure thepadapring Indooblabootlheamounl oflriclioomalerial leI!. mNSIXe lhelhieknessofthemalerial. "~ is l mmor less. lhe pads "","I be 'eplacfld N ol e lhalili s notpossi ble todegrea~th e

lricl"",mat""'"; Wthe pads are contaminatfld In arYf way they must be replaced. . Hlhepads ...eln goodconditiondeantl>8m carelully. uslr>g a line wire bl\lsh which is completely free of oil aneJ grease 10 ,,,,,,,,,,e 1111 Iraces 01 road dirt and corro"ion. Using a poIntfld InS1rument.dean oot the grooves In thelrictionmaterialaneJd'lloot anyembedded particles olloreign matter. Any areas 01 gIaUIg may be removed using emet)'cIolh 5 Ched
6 0r1ZR550B4.B5andB6mode1s.r"""",e al l traces 01 corrosion Irom 1M pad ~n Inspect the ~o 10' signs 01 damage and repace il oec 855aIY 7 Pushthepislon(s)aslarbackinlolhe o;aliperas possible lISir>ghaod 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 calipegsure lhe pads sit Squareiy eilt." siOe 01 Ihe disc {see illustration 7.131. 12 Insl alilhe ca liper mounting bolts. and ligllten Ihem to the specl!ied torque (see IHustratlon7.14b) 13 Top up tile master cylinder ,e.erveir II nllCe.sary (see C/aily(p"H;de)checks),and reservoir cover and dlapllragm I!

;:Ihe

14 Operate the braketever several limes 10

bnng Ille pads Inlo centact wilh Ihe disc Check I"" mastercylinderlluid lev.. (..... DaHy (pre-ride) Checks) artd the opeg the motorcycle

7

~:~:~~c:,1=ati~~oval, ~

"'"

Lll.

'"

:::::,~:: (:.:ac,;'~= ::-:~:

'::.~;f:~~~h,,::r:'::};/::ho~

from lhe syslem. Also, IlMdus lcrealadby

Iha brah syf/emmaycontaln a.beSlo.s, whlch /s htmnfultoyoorlleaJ/II.NfI ...... bIow /I oul wltll compreesad air and don't Inllale anyofil. An approvedfilteringma skshould be wom wh.." working 011 Itt. brakes.. Do no!, undar any Clrcumst"nces, u,e p a lroleum-based,olve nlS to c"",,nbrake

......"....,,.,.

pa rlS.UM c'-"bnlke fluid,bra~e c/ea .....

Ot"dena tured ll/collol",,!V.

lhlss r~ar>d

religfll"" ir lighrly. 11Ieblke·shydrau/k;syslam

6.1Ob .. . and g-uldelarrowed) ara correctly pos itioned

(lIf1"OwedI . •

of

rhe body 0tlC8 lhe pad$ ,.,"" bMn mmoved. Disconnecllhe hoseoncalhe piSlOnS/lava bMn""ffldeort)'di$pl8Cad.

2 Unscrew thacalipe< mount ing bolls . and

sllda the cal ipe, away Irom Ih e disc Isa. lIiustratlon s ). Reme •• lhe brake pads Is"" Sec lion6).andthepi.tonln.ul ator~ecels)

lsee illu. trlIt1on3.2b)

Overhaul 3 Clean the .. teriot 01 the calipe< with de""lIlredalcoholo ' bra k es~lamcleaner

lseaillustratlons) 4 Removethepislonsl,omlhecallpe8m oot by operating the Ironl braka lavaruotil the pis tons are displaced. ot by lorclng them out using compresseclair.Notethat on750rn<>OoOs.twe s izes 01 pislon afe used. and that different s ize seals a,., usfld accordingly. Maf"keach pisten head and callp8r body with a lell marker to ensure that the pistons can be

6 e lO Brakes, wheels and tyres

7,3a Aearbrakecaliper

I /nnerpad 2 Outerpad 3 CaliperbrBcl<et 4 SJiderpinboot 5 SJidarpinboot 6 Caliper body

co~:a: B1 ,

7B1&advalva

•

8 Padspnng 9 Du313881 II

;:,::;orpiece

12Pi3tonseal

7,3b Rear brake caliper components· ZR560 84, B5 a B6 models

I R-pin 2 Pad pin 3 Innerpad 4 OuIerpad 5 CaliperbrBcket matChad to their original bores on reassembiy.lfthecompressadairmethod is used,placeawadolragbetweenthepistons and the caiiper to act aa acushion,then use compressed airdiractad Into thelluid Inlet to force the plstoos out of lhe body. Use only low pressure to ease the pistons out and make sure both plstoos are dlsp!aced althe same time. H the air pressure is too high and the pistons are forcad OUI,the caliperandlor pistons may be damaged

At..

ili

Warning:

Never place

:~e::;o;:,'

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 Se<::tion 4 o f this Chapter. noting thet the dial gauge should be atlached to the swingarm

Remova' 2 Remove the rear whe91 with relMence to

Section1S. 3 Mark the relationship 01 the disc to tt>e wheel so it can be in s t~Jled in the same position . Unscrew the disc retain ing bolts. loosening them a liUte at a time In II crlsscrosspattem to avoid distoo1fng the disc. and remove the disc (see IIlustrat1on)_

Installation

pisloosallthewayin.maklngsuretheyent9l' the bore squarely (see Wlustration).

Installation 12 On all e ~cept ZR550 84. 85 and 86 ITIO(Iets.lnslalitheplslonlnsulatorpieces (SH Illu stration 3.20). Install the brake pads (see section 6). 13 Insta ll the cal iper on the brake disc making aure the pads sit squsrelyeither side of the disc (seeliluslrlltlon) 14 Install the caliper mounting bolts. and tightllf1 them to the specified torque (see illustration,).

16 Fill the fluid reservoir to the upper level line with the specified brake fluid (see illustration 5.24) and blaed the hydraulic

.. Pos~ion the disc on the wheel. IIligning thl! previously applied match marks (il you're reinstalling the original disc). The arrow marked on the disc must be on the outside and point In the direction of normal wheel rotation (seeWtu,lratlon). 5 Install the disc bolts and tighten lt1em in I criss-cross paUem ev8l'l1y and progressively to the torque setting specitied at the beginning 01 this Chapter. Clean off all grease from the brake disc using acetone or brake systemcteaner. If aIl$Wbrake d!schesbeen Installed. r8I1'IOVe any protective cQMing from ~s wortOng SlJrfaces. 6 Install the rear w~ with reterence to

s~temudesaibedinSectlont' .

Sectlon1S.

17 Che<:k very carefully for leaks and thorough ly lest the operation of the brake. prelerably before taking thfl machine out on the road.

7 Operata the brake pedal several times to bring thoe pads Into contact with the disc Check the operation oftha brake. prelerably before takir>g the mochine out on the road.

15 Connect the brake hose to the caliper. using new sealing washers on each side of the filling . POsition the hose u noted on removal (see illustrations 7.1 and 7.2b) TIghten the banjo bolt to the torque setting specifoedatthfl~lnningoltheChapter.

6

8.4 The arrow must point In the direction 01 normal rotation

6- 12 Brakes, wheels and tyres

9,6 Remove Ihe split pin (A), withdraw IhfI clevis pin (8), and separate the pushrod from tl>e 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
=t!'c=:::~Icn, then the caliper 14n""ltJir
O·nngasanewonem~Slbeused.lnspec l

the'aservoi,hose fo,c,acks",opl itsand ' epjace ilnecMSarY. 15 The piston assembly arid spring are "'dueled In the ,ebuild k~. Use all 01 the ......... :=~=lessolthe~conditionol 16 Instsll tha spring in the mastercyi inder

w~h ~.widerendfirst so that ~.tapered end !""""thep;slon. 17 L~b
6-14 Brakes. wheels and tyres

11.11 Mak. s ..... theplston.s.semblylslns .. lledwlththe

inne,MdlAllac;"g;".andtheoulerMd!B)lacIngOul 18 Inslall and dep<esslhe pushrod. then install a newcin;I;p , making wre ~ Os ptopett)t &ealedil'lthegroove !SHilluslratlonll.l1) Ig Install lhe rubber dust boot, makingsu", the lip is seated properly In the groove !SH iIIust'ationll,IOb) 20 Il removed,titanewO-ringinto thefluid reservoirhoseeibowsocl<et !SHlllust",llonj, lheo inslall the elbow inlO the mastercy1indet er>dsecurertwithttscirclip !seeillust",tion

the elbow on the master cylon, Ensure that Ihal>ose iSpo$ition.ed as noted on removal !SH illustrations 9.4a and b) and tighten the

11.14)

25 Align Ihe brake pedal with the master cylindetpushrodclevis, thenalideintheclevi$ pin and s8Cure il using B new splil pin !see Illustrallon9.8), lltheC""-ispositiononthe pushrodwasdisturt>eddu'ngoverhaui,re-set the brake pedal to i\s speci'ied height !see C/;apter I,Secbon 13).

Installation 2t II removed, inSlallthec""-is!ocknut, the clevis and its nut onto the master cylinder :~~~end, but do not y.t lighten the 22 Install the mastercylind
Chapter !SH lllustratlon9.7} 23 Ilremoved,securethelluidreS
c"""".

banjobolt tot hespecihadlorqUflset~ng.

26 TIgh t entheclevis~u t secUlely

21 F il l thell uidre""",o irl othaupper~vel line withth.speciliedbrakelluid !se. illuSlrallon9.5)afldb4&ed lhesyst"", 1~lowinglheprocedureil'lSectiontl

28ChlK:k lheoperationoithebrakeeareluily belon!lrldlngthemototeyCie

Inspection 1 Brake hose condition should becl>eck&d

regularlyaod the hoses replaced at the

i:~ ~ervf~~~;~:'l) 00585 whi le looking lor cracks, bulges and sooplng lIukl

~~: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 CIlapte<.MakeSI.Qtheyarecorrectlyaligned androuleclc:tearoloillTlO\Oing~

6 Fl\Ishtheotdbra!<efll.rid lromthtl'YSlem, relil l with the recommended Iluid (sea Daily (pre-rldeJchacl<51 and bleeCI lhe";, from IhtI system (ue SectKln 't). Check the operation

--.

01 the brakas carelully belOfe riding the

11 Brake system bleeding

~

.. lf blMdlnglhe ...... br.I<e,rernowolherl!trt: : e p ar>el 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 oneen
: .=

blMdingptOCeSS. 8 Care\ully pump the bfake laver or padal thr"" Of 10Uf times and hold It In (front) or

caliper, and on lhe 750f8e< caiper. also blaed the system via the olher bleed v'l .... eon the caliper. 10 Ins tall the diaphragm and c. p/cover assembty,wipauPlNfspilecl brake l!uld8tl(f checI< the entire Iystem lor leaks

12 Whe&Is -Inspection and repair: ~

~ 1 In """" 10 carry out. properinspeolion 01 thewheels,Misnecessar)'1oSlJPPO'1 lhebik' upl1ghtso that 'he ~l batnolnspecledls

rBised off the Oroo..nd. Position the motorcycle on~scentra.\anclor an .uxibry stand.CIean

thewheeisthoroughfylOrernoYedin Chepterl.

~leva":"~~~=ebln:: :w~::~a ad:; :~.:~s:: ::n~::

~ ;:£~~~~~~:: r'"-'-"-'"-',_,m_'H_,_",_" ,,_, , _tIO_"'._'_Pin-,'" 1 Blaading the bfakea Is simp/y the proCfIU

!AI

\I RetlghlEl
oI.IImOVirIO',II1hellirbubbieafrom1hebrakebrak. l e v e r o r p a d a l g r a d u a l l y . R e p e a t t h e j

:::::,~.:,;.;~: ;:,::,~'w~".'.!'!': ::::::".:'~:::,;~,::::.~..:"::;

:~:,~ ~I::ti~~~!. .~:I : IU~~~~:

=

::.t:!!~pannl!1" 10 lit

:rK1~II?:I:''':~=-

brake system hydraulic connection Is klosened. wh ..... comPO"'"t Or hose II replacad, ot when the mastl!1" cylloo ... or caliper Is OVI!1"h.auled . Leaks In the sys tem may alSO.1low air to ent.... but teak;ng brake fll,.;d wilravea/ theirpresenCflMCIwamyouol theneedlorrepatr

2 To bleed lhe bnlkes . you will need some new. clean DOT 4 brake lluld .• length 01 clelr

Ihe brake ClIliper

~!>~t;u;e:~~ d~l:'tt!':: IlIalbrake lluktisspiDecl

I,;

pedal IS Ilrmwhen applied. On compleUon, disconnect the b1eedl"O equipment. lhen liglllenlhebleeCI"atvetolhatorquesettlno specified at the baginnlno of the chapter &roc:f Install the dust cap. In the CIlSll 01 Ihe lronl braKes. alwayt: 00 on to bleed the oth ... •

IN

.

I I!il

•

=

HIt"notpouJr».toproduca a firm fHl 10 III. Ie.,..- 0.-

~::a./'::t :::'idbra~: flU~

~::~~l!bleS

,:::.:u-::

in fII. 1t'S1_ Ita ...

lUCheckthewheellorradlal(ol,l\-oI-

round) runout IAI a nd ulel/sicla-to-sldaj ~I.

6 - 16 Brakes, w heel s and tyres wh .... lslow'Yandchec" the axial (sld"-to!Iide) runout of the rim. In order to accurately checl< rar;Ual(OUIoiroundjrunoutwilh theoial gII'-'9II. the whMIwouldha"" tobe .."oo.1KI Irom the machl"". and the tyre from the wheef. With lI'Ieaxle ctampIKI In a >iIce 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

::,,:;gSV
~~.other

4 The wh .... ls Shovld al&o be .;su-ally ins.pected/ofaacks. llatllpOlsOIllI'Ierimand other damage. On all cast alloy wheef., look very closefy for dents in th""'eawtl"'lI the ryre be8d contacts fhe rim. Der1ts In thi$ area may p!"event complete sealing 01 the lyre againsltherlm, wtIich leads lodeflation 01 the

"" upright position , either 00 i\$ centre stand orOllan auxiliarysland , Measurall'le widlhof bo\htyr8$atthllifwidesl poinlS. Svbl,act ll'le small'" mea.y.ement from fhe larger

Z:1~::,~rora 1r::'utOflntl~~he~f d~:~~~ :: eXCfiS;"e.lI'Ie_wtnlla""tol:>ereplaclKl 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 ab<.ogeecord

:::~e~r~n!!I~C~~h::= lfOmthe cal;per 3 Slacken II'Ie IllCIe clamp bofI 011 the bonom of Ihe right-lland side fork. then slacken the axle ilSel1(right-hand end). while counterhoIdingthe """' nvlOIlthele1t-hand_ (.... Illustration)

14.3 "" Je c lamp bolt (AI,uIe (8)

Brakes, wheels and tyres 6- 17

.. . lIfIdthe--.-terdrtvtl hous ing

14.14 , .. and the axle clamp bolt to the

14.13 Tlghten the axle ..

~ifi8dtor"""Htting

4 Position the mototeyCleoo itsceotre stand

~':':=:I~:~r:.ea:.~=:~o= grnund ,Alwaysmak"""",themolorcycle is prop«tyauppor1ed. 5 Supportlhewheel,lhenlullyunscrewlhe axle BOd withdraw ~ lrom the figh t-hand side and carefully tow&< Ihe wheet (, ... Mtustratiool· S A"move lh" wheei spacer Irom the nghthand side 01 Il>ewheei. noting which way round II lils, and Ih_ speedomeler drive housing lromthele1! (_ lIIustrationsl. Not"

~ne:~=. lile !fOII! btltI<e lever with the

=;~n~D':;;'o:,.~~~";'t!e

:nc::

bKoma ..,lIrpad.Sllllhll whlllllonwO<Jd blocks s o Ihll d;s c do"sn'l support Ih"

weiQhfof thawhHI. 1 Cl\eckll>e axle fQt stra;ghU,..ss by roIJing it ooafllltsurlacesuc:huapieceolplategw.. (lOrst wipe oIf all old g,ease and ,smoveany co"os kln using 11M em<>ry clothl, II tha equipmenti •• vailable . place the axle In Vblocks and measu,ethe runoul using a dial gauge . If Ih" a><18 is bftnt or Ih" runout ""ceM!s the limit spscffied. replac.. it 8 Checkthecond~lonoflhe~bearing .

andbearing_~(_s..ctlon161.

Iftsf.lI.tloft 9 Clean the speedometet drive componenl!

and appiy grease to the dnve gears. Fit the

s peedomet&< drive hous ing to the wh&ef 's lelt-hand sid" . aligning lIS d,lven gear labs witIIlhe slots in the dril/e unit in the oob ISM i"""tration14.6bI. 10 App/)'8$f1'1811(ol grease 10 the Inside and 8ndsotthe~Spacerandtot hel ipaoll he

b8ar1ngsearln lhehub,tllenfittheSpac&
11 Apply the lrootbrake a lew times to brirlg th .. pads bac ~ inlo conlact with Ihe d i"" •. the mototCjlc le olf~ s 5tand, apply the 'ronl bra ke and pump the lroot lorlls a lew limes to setfJeall componeotS in pOsition. 18 Check lor cOfrect opwation 01 th" Ifonl btake be/",.e riding IIIe mototeyCie.

MO\Ie

thewhe8f I_III""trlltionI 4 .6a). II

~aooeuvrethe~ in t OPOsitlon,AppIy

15 RearwhHl removal and instaUation

alhlncoatol~totheaxle

12 Lift tlle WhHI. maki rlg sure Ih".pace< remains In place. and slide the axle Into pos ition from th" fight-hand sid" (sa .. lII""tratiool4,51. A1;gntl>eapeedoroete
13 Count&r-holding the axle nut 00 the 1e1!hand6fld of th" axle. tightlln the axle to lhe

:;:~=:"~:.?li:.tebeginnlngOf 14 rlQht .... the axle cWnp boll on Ihe rigIrthandsidelori
15 Install lhe btak" caliper. mal
muslmtlons 3.13and3.141.

16 Pas. Ih".paedomete
Removal t Position lhe motor¢y<;leoo ~sceo\re stand or an IIUxiliary sland. Remove the chain guard t_Cha;lt"' 7).

_

_

-

_ _...,-

8

6-18 Bfakes,wheelsandtyres

2 su.ck..,

eacn chain

td/USH'f

CI¥np I>0Il.

S':r«=~:=::::.:?~:; PfOI>ahIyIlncl.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::

.............. _<_-..IonI

=-

• I\omooe ..... .....nngdjpfrom 'holoft_'->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",,~,,::,(=

Brakes, wheels and tyres 6- 19

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
ltIustration 15.3b) and tighten it to th& specified torquttse!ling. counter-holding the axle head on the other sid& of the wheel ISH illustration). Frt th& retaining clips onto each end of the axle. making sure they fit correctly Intotheirgrooves (seelllustratlonI5.3a). 12 Adjust the chain slack as described in Chapter 1. 13 Operat& the brak& p&dal se~erallimes to bring the pads into contact with th& disc. Check the operation of Ihe rear brake carefu lly befor&ridingthe~ke.

16 Wheel bearings - removal, jnspection and installation

Front wheel bearings Note: Always replace rh& whe&/bearlngsin pairs. Nevarrep/ace rh& beaIings individually. Avoid using Il high pressut{l cleaner on the whe&lbearlngS(flI1.

6-20 Brakes, wheels and tyres 1 Rem""" th" whM! r_ Seclioo 14) ra ... IlluslIatIoo). 2 Se1 the wheel on blocks so ss 001 to allow ~:we+ghtof thewheeitorestonth"braI<" l Usiog.ftat-bladed~. removethe

grease seat lrom theo right·hand side of the whN itlu511a1lonj. Discard the sea' W~ is

r_

in any way damaged Of deteriof"ated as a new

one should be used. Kawasal
haodbe.aring.t ap"."nIyB,ouodthe lnoe, race ollherighl·haod bearing 10 drlve~ from Ihehub (I ... Iliu l t.atioos ). The bearing spac ... wii also come out 5 Lay the wheel on ~s Olher side 10 that the .emelnl ng bearing laces dowo. Drive the bearlng out of the wh",,1 using the Slme technique ss aoov..

2 Speedometer driWJgtJMlIousing

lCirtiip 4 5pMdomew dt/Ve

6 H the beariogs are 01 the unsealed type or are ooty sealed on """.""'. clean them with a

high flash-poinl solvent (one which won't

16.3<: ••• "rId.emove the Speedometer dri .... (lIrrowed)

..

1!1..4a Uslng "drift 10 kr10ck out the '"~

16.4b Loc.ate thttdrlftllsshownw!>en

drtvIngoutthttbearing

Brakes, wheels and tyres 6-21

leave any rHidue) and blow them dry with compressed air (don'l lei lhe bearlngs spin as you dry tllern). Apply a few drops of oil to lhe bearing. Note:/ffhe be8tingis sooied on both skJes don'tallempl 10 cJean ir 7 Hold Ihe Ollte.- race of the bearing and 'otalethe inner race- if the bearing doesn't turn smoothly, has ,oug h spots Or Is noisy, replace~wi thaoewone.

S if thebearingisgoodandcanbe'&-used. wash ~ in solvent ooce again and dry~, then pack the bearing w ith high metting ' point greaS
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

Spro<:ke r coupling bearing 23 Remove tile ... whaeI lseeSection 15) Uti tile sprocket arid sprocket coupting -..tIIyOUlollhewhell. noting howlt ilia ,... 1IIustraIlon 18.12bj. 24 Rtmcwethell**fmmlhlt_afthe coupling bNrIng. noting..nidl way round ~

m. I...

areoM'lNIed on one"', c""" them with a ~;g~ flas~·POInt

22 CleanoOlt.lfgr. .se f,om tllebrak.dlac

uslngacatoneorllrablyslemdeaner.lnstal

INve any rHIItue) ....:I blow

lON.... t (one wtli<:h WOO't t~em dry with

tlle",'aprocklt arid oprocket coupling

~_fo;Ion'tletthe*'-ings",*,,,

aasemblyontotl>e~.lhenlnstallthe

you drythen\l.Appfy,"'dropsoloil 10 the

wheIIl_SectiorII5).

Mlu str a Uon'I .UsIng.llat.~

!IC'f8WdrfyIO'.prilaOUlthegraaseMIIlromthe OUIlideolthac;wplingl... lIIustrlItIon).Kthe SNlappaarwl'I)Ck,mak,,,,,,,,thalipoOfthe screwd ....... Is not catching undet \he cltcllp. DiscBrcI the MIl N~ Is in ""'I way (!amaged or detarlorattaw """" as s matt ... otOOUf'M,Ualng.pgirofintemalcirdjp pt ...... rer\'IO\I.thadrclipsec ....lngthaw""' beaMg in the nut! ,... 1IIus1ralionl 25 Suppor1thlcoupllngonblocksolwood ....:f 0rIv, ballring out from the insida

"'1

beaMg. ~ ,"rn.~ ;,_on_ sidotsdonl.~IOe/Mn/t.

18 Hold tlMo outlO"_oOl tllebPring and rou.tathe ........ _·~lheburingdoesn'1 tum smoothly. flU rough spotl Ot Is noisy. ,~~wiIh.'-one

19 HthebeaMgil;lIQOdandc:anbe rlHlMd. wasll~ in~ tonc.lOeinanddryit,then

~k t h.

bearing with h;ghmeklng·point

graasa. Ka w.u.kl recoOmm.nd thaI Ih. ~~Cltclipshouldbe r~IIdW they

20 Thoroughly c'-.n th. hub ..aa of the the rIght·hInd side beaMg

wheet. Fht

_~

intoitsreceuinthehub.wilhtlMomtll1<edor ....ledlidefaclngoutw.rd,. Using thtI old belrlngQfnewone. ... being tltted).a bellring d ........ Ot. lOCket large enouoh toO conr.:t thew!. ' - 01 the beaMg. drivelt insqua-elyunIJit'.compIetely .... tlld (... iIIustntIon l S-S.J. F"fttheo;:irgjp,making .... il I,correclly H.tt
\he lips 001 \he buring .... and Plesa ~ inlo Il>erlghl·ha rld lldeoOltllewl>H!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

Brakes, wheels and tyres 6- 23

16.25~t"-bearingoutIrom Ihe 1n 5ide

16.29aDrMot"-bNnnglnuntil seatlKl

uSing a socket located 0<1 the bearing inne< raee l st. lliustratlon). DQ not remov. the bearingunle55anewonei'beiogin.t<M1ed 26 nthe tJearing is oft1>e unsealed type oris 0<11y seallKl 0<1 one side. clean it with a high l\ash.poit1t solvent (one which won·t leave any r'9$id ..... ) and blow it dry with compressed eir (don1Iett1>ebearirogspinasyoudryit). AppIy a lew lIrops of oil 10 the tJearing. Note:/lrhfl

29 Thoroughlyclean thebearing receout",,,,,,,,oft1>e bearing,e IOpsof the bearing seal. and press it into the right·hand .ide 01 the wh"" using yourfongers. a seal or bearing driv&r. a suitable socket or a flat piec. of wood (see lllusiretlon). 30 Install t he space< into the inside 01 the c<>upling.mak ing sureilis lhecorfectway round (see iliustraUon 16.24b) . Installth. sprocket coupling assembly onto the wheel (.H IlIu . lralion16.12b) , theoinslallthe wheel (..... Section 15).

=~.seaItK100borhsidoesdon·laff&mpt XI HOld the outllr race of the bflaring and rotate the innelOodandcantJer.-used wash H in soIv9llt once again and dry~ . thefl pac k the bearing with high melting-point gr.... se. Kawasaki recomm.nd that the

:~v:Circl"'sho\Adbe~ifthe)t

l B.29b ln.t"ltl>eclrclip, tlM-npnouinlhe grease .....

17 Tyres - general informalioo andfiHing

General information l 1'hecast....-finedtoZA5liOandZR750C modelS ar. designed to tak.tubeless tyres

only. The SpOI
2 Aele
Fitting new tyres 3 When selecting new Iyfes.

rflf",to tile Iyfe

:or::r:: =~~~rfI~~:';'!~~':

rea r lyre type, are compatible. theco"ect size and correct speed ralin\l; il necessary ,eekadvlce Irom a Kawasaki deale< or tyre f ittings.pecialisl (see illustration)

6.24 Brakes, wheels and lyres 4 It is recommended that lyres aTe only ever fitted by a motorcycle tyre specialist rather than anempted In the home workshop_ This Is particularly relevant in the case of tubeless tyres because the force required to break the seal between the wheel rim and tyre bead Is substantial, and is usually beyond the

capabilities of an Individual working with normal tyre levers. Additionally, the specialist will be able to balance the wheels after tyre fitting. 5 In the case of tubeless lyres, note that punctured tyres can in some cases be repaired, but again, this should not be

attempted in the home workshop. Kawasaki also recommend that a repaired tyre should

not be used at speeds above 60 mph (100 kmh) for the first 24 hrs after the repair, and thereafter not above 110 mph (1 SO kmh). If a

puncture occurs on a tubed tyre It is advisable to have a

new inner tube fitted.

'" Chapter 7 Bodywork Contents Chaln~d - removal8Odinstaliaboo ... Froo! mudguard - removal and Installation Gflner8linIOffilaboo ... ...... , .. . . .. . .. ... .. . Rearcove
. .. 6 5 . ..• . • . ~

Rearvillw~-r8movaland lnsta ll ation

2

Seat - removal and instaliaHon . •. . .. .. . . . . . .. . ... .... 3 Side panels- removal and installation " . . 4

Degrees of difficulty

1 Generallnfonnatlon

trim nuts or clips and damping/fubber mounts: any of these must be replaced ifl aully belore thdpa~ isreassembJ&d . Checkaiso thatall

This Chapter covers the procedures necessary to remove and install the bOd y parts. SillCe many service and repair oP9'ations on these motorcycll'$ 'equiretlle removal of the body parts, tllep
fasteners are in good cQndition, including all

mounting brackal s'lr", straight and repajror r~a~ !ham il necessary before attempt ing 10 instal l th ... paM!. Where assistance was

~:I~~t ~;:,~ ~~~:,'i ~~ak8 sore your Carefully stlttI$lhe panel in place, following the instructions provid9d, and check that it engages correclly with its paftner& (where applicable) beforB tig htening any of the last8l1&rS. Where a panel engages 8IIOIhiIr by maansof talls. bflcareful not 10 bO'eak the tab or ils malr.g sIol Note lhat II small amounl of lubricanl ~iQoo soap or similarjapplied tallle mounlingrubbers of the s>depanels will IIssiSI thepenel retaining pegs to engage wilhout the need for undue pressure Tigh ten the fasteners securely , but be careful not to overtighten any of them or Ille panel may break (oot always Immed iately) doe to the uneven slress.

2 Rear view mirrors removal and installation

Removal

~

'"

1 Unscrew tile mirror using the lower nut on tile base of the mirror m oun~ng and remove ~ fl'om the handlebfir (He illustrationl

Installation 2 Install the mirror into its mount ing and screw it in unti l it is fully home and tight. To adj;.Istlhepositlonof tllem lrror. counter-hoI<.f !I'H!I lower IlUt and slac k9l1 tile upper nut. then move Ihe mirror unt il it is as required, then tig\1!en the upper nut against tile lower nut

3 Seat " removal and installation ~

~

Removal 1 Insert the igni ti on key into !Ile seal lock wh ich Is located under Ihe left -hand side pane!lIOd tum it clockwise to unlock the seat (see l6ustratlonl

7

2.1 Unscl'1lwthe mirror using a spanner on the nut (arrowed)

3.1 Tum the key clockwise IQ unlock the seat

2 Uti the rear of the seat and draw It back and away from the bike. Note how the tab at the front of the seat locat es under the tank mounting bracket. and how the _ t ~at&$

grommets lsee INustration). Do not bend the panel while removing it.

tore. or

Instal/ation

onto t he~ klng ra ll

Instal/atlon

~ •

the I..... tank mounting bracket (see iIIustraUon). Align the SI3t at the rear IIoI1od pu$h down on It to engage the IIItehea.

I

A amea,. of liquid sup applied 10 the mounl/n" grommeta will help the side

penel and rear co ..er peg. eng/l(/tl without the nHd for unduepressuf8.

4 Side panelsremoval and installation 5 Front mudguard removal and installation Re m oval 1 Remove the MIlt ~ Section 31.

~

'"

2 Eaehti
Removal

whlehareepre$S-lItlntorubbergromrnetlon the ITame. Gently pull each panel aWIY from the frame to release the pegs trom the

1 Remove the Ironl wfleeI lor ImprOVitd access. Wrequired (see Chapter 6) 2 Carefullv pull the press-iii brake hOle

guides /rom the mudguard. where fitted lsee iltustration). Unscrew lhe lour bolts securing the mudguard to the fOfks, noting the position of the brake hose andlorspeedome!er cable guide (see illustration). Caretully remove the

=~~:~ from betW&ef1 the forks, nollng

Installation

6 Chain guard removal and installatfon

Removal t Un$Crew the ltv" screws $&Cunng the chain guard to the aW\Ogl'ml and remDYethe guard, notinfi/ how It fitl lsee ~tustration)

Installation 2 Instal!ation is the reverse ot removal

3 Tho_W;etISMcu..:ltry_~

?p.

i:: ~ ~=~~~"'7':two

boll • ...,...;"gtlle_gr_,aiI.IIW1,omDV
..

.... """'_.ondtry''''''''''''' ..nc!I ....

=~U:'I<::-k>t~.~:o~

..... _.."..,..-.CI<eI.... U..... WifIt<.tl no

.... t*lig/lI_""'_ ...

' 1<>5'_''''''''I'l00,.._01 ,,,,,,,,,,.>1<~_-,"" """""'_~

8"

Chapter 8 Electrical system Contents Memator·nImOValandinstallalion ... ...... ....... ... . .. ... 34

Sanery·charging ....... . .............................. 4 Ballery - ",mov".j""ta/IatiOn.lnspec lionandm al nte na~ . . .. 3 Bral< eighlswilches - chod
14

Cart:>..o"ettor heater system (UK later models only) • ""edding ..• " ..... __ .....•.. • ...... 2 Fueilevel-.::l ... ·cIleck andrepl.....,.,.,..-,t .. . ...... 26

....

=~~~repac.rntnI Handlebarswitcl\es·check . ........... l
:::=~-\:!.~'::"'":~lat';';':' "

~

. .. 20 . . . 21

.. see~.~~ ~

Instrument and warning light bulb!! • replacement .

. ... 16 . .... . 25

.6 Neutralswitctl - ch&ck,...,..,..a1andlnstallatioo . . . . . . 22 Oil pres!llJre swileh -dleckaod repIacemen~ ...• . ...... 18 Regula~orlreclifief -checkaodr~.. . 35 .24

Sidestandrelay - checkandreplacemeot... Sid""'andsw;Ic~· Ch&ckand repJacemanl ... . .•..... .•• Stan... motor·d_~.inspactkln_re""Hmbly.. SIMIOIfmotor - removalaodlnstailatkln . . StartOlf relay - check and replaCemen~ ......... T"Iig~~assembIy - remcwal_replac_nl.

TaiHigh~

bulbs - replacement .. . . . . . . . . . . . . . . . . .

HeadI~bul>.nd_ l igtttbolb-replacem"".

Tum signal ass...,olies . removalandlnsta/la~Oon. T.....,slgnalbulbs · replac ....... '"

Hom-CheCk.odrep~ement

Tumslgnalclrco i ~ -

. .. 7 ..... __ .......... . ..28 Jgn~ionf""'in)!Iwiteh· Clleck,AIIOOvaiand ins, aj lation .. 19 Ignilionsyslemcomponents . .......•.. . ...... oeeChaj:lt",4

... 15

Ins=~:=t~~~Instruments - check.r>dreplacemem. . ... Junctionbox-cMckancl~""""'~.. Lqttlng~""'-clleck........................

..23 31 . 30

.2"9

..to . . .. 9

. .. ...... 12

. . ...... 11 CheCk 13 Wiringdiagfams . . . . . . . .... ... ........ . ..... endofCllapler

Degrees of difficulty

Specifications Batt.."

"""~

12V.I2Ah

..... .. .. ............... . a.ctroIy!espec;licg' ..... iIy·ZR55QSt.S2.B3and84mode1s .

1.2SOatro'C

~~~~2~B3.~.~~~

12V.lOAhMF{mainteoance-lree)

Fuses Malo •.... Headlight Tailighl ... ..... •.....•.. . Tum 590al (\at. mod .... only) Igni!kln(\atetmodelsonlyl Hom (la1. models onM

"".......

ZR550 (all modelS), ZR750 Ct. C2 {UK} andZR750CI tQC3{U$lCanada) ............ . ZR750 C3. 01. C5, Dl (UK). ZR750 C4 (CMada) ..

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

Bulbs

"'" ""

Headlight

~5WH4~aIogen

SId.. 9~t{UKonly)

Br:':

USmodeis ....

T~::r'"

"'''''''''''

2115W

""'"

8

8-2 Electrical system Bulbs (continued) Instrumeot ligh!s.USZR55(lBI a nd 62 SJ>-jome'terand tachometer

WaminglightS .. Instrumeot lights- aUothermodels Spee(jomelllO".

-

Tachometerandwaming lights

,.uw

Fuel level sender 4!O 10 otvns !IO!O l OOohms

Fueltanklutl . Fuel tank emp(y

Carburettor heater system A~r\c!empera!""ser1sorres/$tance

Rislnglempe
from zem to Inflnlle between 7 end 13"C

.

l1"omin finl! e loz"",,~3·C

OiIwnperakJre$ellSOfre$i$l1lllC
Aisingtemperat ....,

fromze
Fallinglemperature .•.

lmminftnileloz"""above33·C

c.::::~temp
2.9KOI1ms U!o5.2Kohrns

211O"C

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 re<:tifie< converts theac (altematingcurrent) output 01 the alternator todc (direct cUl'I'ent) to power the lights and other compon""ts and to cha ,ge the bllttery . The alternator rotor is mounted on the left -hand end o f the The sta rter motor is mounted on the cranl
components or circuits lail at one lime, chances are the lault lies in theluse or earth con nection, as several circuits otten are routed through the same luse and earth. 3 Electrical problems often stem Irom simple causes, wcll as loose o r corroded connections or a blown fuse . Prior 10 any eleclrical fault linding. always visually ch&ck the condition 01 the fuse, wires and connections in the proOlem Circuit. Intermitt6llt laifu,es can be especiallylrustrating, since you can't always duplicate the failure when it's convenient to test. In such situations. a good pract ice is to clean and check all 01 the connectionsln theaffectedcircui\.wttetheror not they appear 10 be good . All oj the cOIYlfICtionsandwi,essl1ooklals.obewiggled to check for looseness wh>eh can ca use interrnittentfai lure 4 It lesting instNmenls are going 10 be util ised,usethewiringdlagramsattl>eendof 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
Removal and installation 1 Remove Ihe seat (see Chapter 7) . On 750 models, a lso remove the fuel tank and the tank b rack et, then remove the Iwo SCrewS S8Curingtheairfi~ ercowrtolhelilterhousing

and lilt off the cove r (see Chapter 3) (see Illustration). On ZR550 B5 and B6 models, remove either 01 the side paoelsand unhook

~~~~c':wba~~ $t~~mioal

screws and d isconnect the lead s Irom the battery, disconnect ing the negat i~e H l erminal first. and noting that thepos~ive( + ) temlinal has an insulatiogcoverwhich must be pulled back (see il h.lstration) . 00 ZR550 Bl. 6Z, 63 and 64 models, disconnect the vent hose ffom the side of the battery. Unhooi<. the rubbe< strap and lill the baUery out of its box (see illustrationsl 3 On iostallation, clean the battery lermioals and lead ends with a wira bn l$h or knile ancI emery- paper. Reconnect the leads, connecting the pos~ive (+) terminal first , then

2 Electrical fault finding

&. :=~~0!~~::E~~: 1~~!

and the ballery negallve (-J terminal s hould be disconnrx: ted be fora any of the bike's othe r elec/rica l components are diS!urlHld. Oon'! fOl'g4tI 10 reconnect Ihe terminal srx:urely 0IlCCI worlr Is finished or if batt,,!)' POWfll" is needad for clrcuilt&$ling. 1 Atypical electrica l circuit cons ists of an elect rical componen t, the switches. relays etc. related to thai componeni and the wiring and connectors that hook the componenl to both I he b attery and Ih e frame. To aid in localing a problem in any electrical circuit, refer to the wiring dlagrams at the end 01 this Chapter. 2 6elore tackling any troublesome electrical circuit. lirst stu
3.1 On 750 models, remove the air lifter cover to acces s the battery

3.2a pun back Ihe insulating cover to access th., positive (+) terminat

_

8- 4 Electrical system lit the Insulating eover OVef the pOtitl".(+) terminal (see illultTation 3.23). On ZR550 Bl. B2,B3andB4rnodet,.cooneclthevenlhose

4

Battery-charging

..

lothe~ofthebatte
componenls in a r.ven. 01 Ih. removal Ca ution: B . ",'re /mll)' c'''''ul wh.n h.ndllng or wor~ lng . round the /)aU.ry, Th • • ,.drolyt. II ~.ry causlic and a n expfoslva gas(hydrooan)lsgivenoffwhan

th. battaryischarv/ng· 1 Remov. Ih. baltefY (see Seclion 3). Connecl the charger to tile baltefY. making

sur. tkllt Ihepo$itiYe(+)leadonlheehargaris eonnected to the poIi!lWI (+) terminal on tke Inspec tion and ma intenance 4 The ba!lery f;1Ied 10 ZR550 Bl . 82. B3 and B
other models is 0 1 tile ma intenanC.-fre
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
the battery muSI be removed, disconnecting thenegativ.Hterm!fIalfirst,andrec/'larg!ld as described baIowin Section 4

bat1ery. and the negativeH lead ilconnected 10thenegaliveHterrrinai 2 OnZA550BI,B2.B3andB4rnode1twltha conventional battery, Ktlwasaki recommend thaI the balte
3 On all other model' equipped with a seale(l mainlenanc.·lree baltery, Kawasaki recommend the ba1le
--.

b)lIrhel'OitageG/:le~11.5andI2.6V,

Charge the I;lIl1tery al 1.2 A 'or betwHn 10 and 5 houI3. according 10 the voIlsge

4.4 11 Ihecharg.r doesn't have amm.t.r bulltln,eonne cl one In aerlel as shown. DO NOT connect the ammeter between thebattefY t~I'lIf'ltwilibaruined

B3andBwpeG

byfllrfhewermlJ/hOdolctwurJingfhebella.y.

5 II lherecharged battery discharges rapid'ty if loft disconnecled it II likely thaI an Inlemal sh.ort caused by phySical damage or suiphalion has occ:urred. Anew batle
c)/llIMttfO//ageGbaIow 11.5V.anlnllial

hIgit'o"Oltageifl:lv!oIabouI25VwlIoe ,.quiredfor~teJyfiveminur.s

belcnthebatterywWacceplanycharpa.

5 Fuses-

check and replacement

1hechargingcu1T8f1lwilldrop./lfldrhe voItageshooldthen/:lereducedunfilthe

CNtrjnOcun-enlllasfflCOl1Vrlflt'l.1f the cun-enl does not drop, a..-bettery isr&quired.

4 Exce«Iinglt1el9Kescancauselt1ebattery tOOVert\eat. bucidlng the plates and rendering ~useIess.F_ownerswilihaveaccesaloan

.xpenslvecurrent-controUe(lcharg .... aoila normal domestic cn.rger Is used cheCk that aft ... apo$Siblelnillatpeal<,lhedlargeral.faIs 10 I $8fe IeYIII (... HIu. tratlon). It the b&ttery

becomes hoI dunngcharging s lop. Fur1her charging will causedarnioQe.OnZRS50BI. B2.

~

...

1 Theelectricalayslemisprolectedbyiuses

04 di:IferenI ratings. AI fuses

arehouMd~the

lusebox. which is Ioeated within the)unction boxunder lhe seal !... lI lua tratlon) . Th. junclionboxalso conlalns ltw s tarterclrcuit r.'ay afld diode. and on US models Ihe headlightrela)r.wtlichahouldalsobetostedin lile event of eJectrical problems (r.ler 10 Section 25). 2 To IICCOSI lhe fuses. remove lile Hal (see Chapter 7) and uncllpthe !usebox lid lsee iIIuatratlon).

lll.JI~~=;i~ 5.2 Unclip the lid t o _ t h e IvHa

Electrical system 8- 5

'./'

'f

fJ~~

~.

" 5.3b A blQwn fuse can be identified by a

5.3aThelusesarea pushflt

break In itsektmenl

I ~n~ 1 )1

1

I

"

8-P,nConn«tOf

5.Sb Fusecir<;uillestlng-ZR550Bl to 85 aodZR750CltoC4mode1s

T....rll ..ding(Cl1

5.Sc Fuse circuit testong · ZR560 86, ZR750 C5 and D t model s

3 The luses can be removed and clle<::ked visually. If)'OU can't pull Ihe fuse out wilh your flngel1lps, lise a pa ir 01 n&edle-nose pliers ' see Illus tration) . A blown fuse Is easily identifi ed by a break In the element (see illustration). Each fuse isclearty mar1<ed with Itsrating andmllStonlybereplacetlbyafuse

occur and cause poor fUH contact. II this happens, remove the corrosion with a wire brushOl'emerypaper.ltleospraythefuseend and t9l1Tlinaiswilh e+ectrical contact cleaMr. To determine whether any of Ihe fusebox circu~ry is faulty. slide the junction box out of

of thecorrecl rating. A spare fuse ol.ach

(see il lustration). Using the tables shown . check lor continuity between the various terminals as indicated lsee Illus!nrtions).

ralingishous&dinlhe lusebox.lfasparefuse is u$&d , always replace II so thai a spare of each rating is carried 00 the bikeal alltim(l$.

Caullon: Nevarput in a tuss ofs higher fsting or bridge the terminal. with any other subslJtute, however temponory it nmy lui. Serious damage may be done to th e

cl/'cult, oranremaystatf. 4 If a luse blows, be surtl 10 check the wiring circu it ve
i1sholOeranddlsconnectthewlring~

8 Lighting system • check

~

1 The balte
Headligh t 2 I1thehe&dI~lfalistowork.lirstcheck lhe fusewiththelgn~ionON (see S8<:tion 5). and then the bulb (see Section 7). II Ihey are both

good. use jumper wires to connect tha bulb d irtICtlyto the ballery termina ls. II the light comes on. the prob lem lies in I hewiring or one 01 the swil ches In Ihe clrcuil. Refer to Section 20 lor the switch testing procedures. and also the wllirIg diagrams at the end 01 Ihis Chapter. On US models. a headlight r~ay is incorporated in lhe junction box circu itry. and I here Is no headllghl switch Incorporated in the handlebar switches. The headlight comes on automallcally when the Ign~ioo is switched on and the engine is running, bul wil l exlir>gl.lish whe!l the sta"er bulton Is pressed TochtICktheheadlight relay in the junction box. 5..... Section 25.

Taillight 3 If lhetail light fa iisto WOI'k . check the bulbs and the bulb terminals first, th6(l I he fuse . th8n check for baltery voltage on the supp!y side of the tai l light wiring connector. II

8

e-6 electrical system

voIIageitpr8'Sef1t,ehecklheellrth(groundj circuit loran open or poor connection. o4 tfoovollageisindicalad.checklhewWing between the taillight and the ign~ion switch. thencl\ecktheswrtch.Alsocl\ecktheligflting sw~chonUKmocIets

Brake light 5 II the brake light fails to work. check the bulbs and lhe bulb terminals first. thl1l the fuse. tllen cheek the brake light Iwitch(see Seetion14).

Neutralllght 6 If the neutral light fails to operate when the traMmissionlsinneutral.clleckthe fuse and tile bulb (seeSeetions S and 17). If they are In good condition. refer to Section 22 lor the neulral switch che<:k and •• placement

Headlight bulb I Remove the two screws securing the headlight rim to theheadlig/lt shell, ancl ease lherlmouto!thellhell.notingllowitfils l see Illustration. ). 2 Disconnect t he wiring connector and remove tile rvbber dust cover,noling IIow It fits lsee Illustration).

3 RelaaselhebuibretairWlgdip.notnghowit lits,thenrlllTlO'i'etl!ebulblsee illuslrlltionsj. 4 FI\ the new bulb, bNMg in mind the Note at the start of this Seelion. Ensure lhat/lbsoo the bulb lit comtclly In the slots in t he bulb ilousing, and see ..... elt with the retaining clip.

S Install the dust cover, making sure il il eorractty seated and with the TOP mark faeing uP. and connect the wiring connector ISH Illustration) 6 Cheek lhe operDHon o! the headlight. lhen Install the rim into tile sI1e/land !;8CtJI"eit with IlIeserews lsealliustratlons 7.1bancla)

Sidelight bulb 1 Remove tile two screws sac:uring the headlight rim to the hladlighl sIlaI, and 8;1,. tile nm out of the shell. noting how it fits lsee Illustration s 7.1aand b) .

--.

Oil pressure warning light

1 If the oif prosure warning light faits to opera" ......... lheo engineisootrunning,cheek theluseandthebulb {seeSeetionsSancll7}. If they ara In good condition. rafer to Section 18/ortlleoilpressu-eswHch checll.

Instrument lights 8 5eeSeetionI7.

Note: Tile Ileadliull/ blJ/b is of file qlJartz1!aJogen!)'pt. Do nor touch /I!e bulb (}fas5 as skineckhJ wiIIshot18111h6 bult>'sservic.-~fe. If /he bulb i$ acQd8nraRy touched, it $hOuId be

wipedCMflfu/lywheneokJwllha'Wi1l<»kedin me/llyl8redspiril(stoddart1~¥l(JcIried

bei'oralilting.

A ,

•

W/tmin,,: AlloW . fI,e bulb lime 10 cool before removing It If the hod/Igll! has lusl been on.

7.5 Fllihe cov .... with the TOP mark uppannost

Electrical system 8- 7

8 Pull the bulbhokler OIJ t ot its soeket in the base of lhe headlight (see illustration) . Pu!lh the bulb down and twlsi lianli-cioc kwise lo retease~ from the bulbholder (!IH Illustration). 9 tnstall the new bulb In Ihebulbholder,lhen install thebulbholder by pressing it in 10 Ch&eklheopetal iof1o!thea.idelight, lhef1 installtheheadtightrlmlntothe~land

secureltwllh l hescrewl (IH illuslration l 7.1banch ).

2 [l;sconneetlt>ewinngCOl1fleClcnfromthe

8 Headlight assembly removal and installation

~ =~~t!i'~~~II~':t~:!~n 7.2) , and the ~

Removal 1 Remove the two sc.ews secmlng the heIIdIight rim to the headlight sheII,andease therimOUIolthethel. notinghow~lits , _ Ilh.ostraUonI 1,1a and b).

3 To l &tl'\OVe theheadlightsh&lI, firstuns<;rew the batt, securing lhe brake hose uniof1 to the bottom yoke, thereby freeing the vertk:al beam adjus ter jlee lIIustlatlon). F,"the wiring inside the !Ihell from any clamps. then disconnect any wiring connectcn neeessary and easelhewirif'lg out It>e back of thellhell. Unsclewthenutsonlt>ein~oltheshell

and fiIn\OYethe bolts seaftIg the shell to the brecke" and Illustration).

remove

the

$f\eoI1

(•••

" ll nacassary, unscrewlhe bolts securing lhe brackets to Ihe support frame and fiIn\OYe tl1e br.ckelS, with the tum signal assembll., anechedorremovedasrequked(5eeliof1t2), To remove Ihe support trame. lirst remove the Instrument cluster (sea Section t5), then unscrew the boll securing the !Iameto the bon omyoke.ndremovethefrsme.noting how It tits {see Illustration).

In.tallation s Installatiorl Is the r"","" of removat. Make sure all the wiring is correcUyconnecledand secured.Checkthaoperatiof1otlhahaadlighl and sidellghl. Check the headligh t plm (see Chapler t ).

9 Tailliglrt bulbs · replacement ~

..: 8 1 Unscrew the two screws securing the tall light len. and remove the lena , see hh.ol tratlonj.

a- a Electrical system

11.1 Tlle tall Ilght leos III secYred by two iJC ~ews (BrTOwed)

1 Ramove the two screws securiflg the lens to lhe tum sigflal assembly a"d remove the lens. notiflg which way roufld It lits (a •• illustration). Remove the rubber ga"",,et alld check ~ lor damllgeor deterioration. Replace ill/necessary. 2 Push the bulb into tlla hold« and twllt It anti-cloc::k-M$e to ramovalt (_ilwtration). Check thasocket terminall lorcorTOSion and clean them if necessary. Un. up the pins 01 \he new bulb with the IIotl In tha socket. than push the bulb Ifl alld tum It c lockwise until ~ lockS into place. Not.: It " a good idea 10 use

11.2 PulhltMlbulbinandtwlsttt anti-eloekwl. . to r llmOVeIt

2 Push II\e bulb In and twist it a"tl-elockwlse to rf,lmove It , see illustration). Check the sockettemllnals lorCQlTOsionarldcl6anthem if necessary. Une up the pins 01 \he new bulb with the llots 1n the socket. than PUSh the bI.Cl in and tum It clockwise unt~ ~ locks Into pIac:<e. No!to:7hO!Ipir4onthttbulb_offWso It can only be inslalledor>e 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<:tly sealed, and secure It with the screWI. Do Mt overtighteflthe lens screws as the leflill

us.,

easily cracked. 4 Install \he seal (see Chapter 7).

10 Taillight assembly -

removal and installation

~ ~=~:;=7,7:.e== blNlftllldtolncnlesebuibife.

Removal 1 Remove the seet and the rear cov ... ( _ Chapter 7). 2 Trace \he tait HghtwlOOg backln:m the tail light allddisconntCt ~attneconfl8Ctor (l" illustration) . 3 Unscrew II\e two nulS securing ihe tail light assembly afld carelully remove It Irom the bike 1_ illwtratlonl. Note \he wring clemp fitted with each nut.

3 In$tanthetensbloei
Instatfation 4 Installation it \ h e . - 01 removal. Check lhe opafallonol the tail Fight afld the brake light.

12 Tum signal auembl5es removal and installation

Front Removal 1 Remove the two iJCf.WS securing the headlight rim 10 the headlight shell, and ease \he rim out ot the shell. noting i'oow it fits ( _ Illustrations 7.101 afld bl 2 Trace l he l um slgnel wiring back !rom the

10.2 Dl$Connect lhetail light -.,.,.,...~

10.3 ThfI tall light alS.mbtyls secured by twonutl(arrowed)

lum signal arlddlscoonectIt at lhecormectors Inside the headlight shell (te. Illustration). Putl the wiring through to the tum slgflal

mounting. notng

itl~.

,~

~!t·11.2 Push the bulb I" afld twist It B"ti-cloekwlse to remove iI

I

11,3 Mak. aora the rubber gasket Is propefty seatedwh. nllttlnglhecover

Electrical system

e-9

12.3 The nul is on the inside of the tleadlighl brackel 3 Unscrew the nul seeuring the tum signal assemb!yto Ihe headlight bracket and care\ully remowtlle assembly,taklng care rool to snag tile wiring connectors as you draw them It1rough tile mounting hole (see Inustratlon).

Installation 4 Instal lation Is the reverse at removal. Make sure the wiring is corree\ty rou ted and 5eCurely connected. Check tile operation of tl\etumslgna)s.

Rear Removal

n.

5 RemoYe the seat (see Chapter Trace the tum signatwiring back from theturJl signal and disconnecl It at ttle connector Isee lIIu etration) . Putl l hewirlng through to the tum signal mounting, releasing It lrom any clips and noting ilsroutlng. 6 Unscrew the nut sllC uring Ihe lurn signal assembly 10 the mudguard and carefully remove the assembly. taking Cafe noIto snag the wiring conne<:tors as you draw them through tl\e mounting tIoIe (see Illustration). Installation 7 InSlallation is lIle reverse at removal. Make sure the wiring Is correctly routed and 5eCurely connllCtecl. Check the operation of tIM tum slgnal$.

orange

13 Tum signal circuit - check

wre. Wrt~ the ignition 00 and the tum

~ ~~~1::=~~:~~~ ~ In each case. Tum the Ignition when the

1 The batte
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:t
3 1I voltaQeII.yalilbl •. rouchtheptoOOof till tHt light 10 tllIothef renninal (bIuewi...)of tlll,wirch . th.., puli lhe brake "",.. In or depresslheDrakepedal:IheC«o:lllCtormusl be joio.d for t~ls cheock. If no reading is obIain..:lorrhet"rl~htdoesn·tlightup.

~Ihe.wilcn.

4 NaraadingllabtainedorlhetestllgttCdoes lighI.checkthewo4mg~theswitctl-'

thebtaqllghlll... tl\ewlringcUgramsat lheendolIhisChapler).

Switch replBCemerJt Front brakt le.er , wltch 5 [hconneoctthtlwlrlngconnecro::qlromthtl switch I' " MI ...tratlon).

:W~,:O;Oe

t::' :!~~! ~;';"7';~~::

mastercylindefand_lheswltch l' "

IM ...tratlonl. II may be .-sary 10 slacken Il'Iebr.k.mUI ... ~ ... low«clampboh and rotall tl\e a ....... bIy on rhe h_l8bar ""'lthtl_IIClMrolthecablesbelorfl~

can be accelllad with I scrawdrlv.... If so. rlght.."h,cl.mpb04ttQ rhetor'lue.elring opecifOld on CCIm!)IeI'=w'I. 7 Installation Ii thtl ,eV&ra1 of ramo".I. The Iwitchlltt'tlldjustable

Rear brake pedal l witch 8 ThaswltchllmounredonlheinsiOeo!lhe Ir.......bo ... lhemll.t ... cylindar l... illuatratlon).Tractothe,wnglromlhelOpol Ihe ,witch at>d dIIconnact ~ .t rile wiring COIWIICtorblil>k>d tIM rigtlr-.....nd side parMI I... lIkn...tJon). RIffl<MIlhesidapanailot IOCCf>N(sMChIIpt.-7).

i o.tachlfltuppet-.cfollhelWilchspring fromlhelwltch.IhlnUf1lCr'eWlheswltch l'"

1I...... IIonI. 10 InstaliaHon I. the re"...aol removal. Make Sure the brake "oht II Icll".ted juS! before Ihe ,..,braka padal lake. eff""t.IT rtdjustmenlll.-allr'\l . l'IokIlheswltchond n.nlhtlrtdjuslil'lgnu1on lhtl.wltchbod)luntif IheDrakaIlgllIIl.ctilllledwhenraquirad.

InstrumerJtc/uster 1 Remove the two SCrawl 1ICurin.g rhtl headlighl rim 10 thtl haadlight si>eI. 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 ... corractIyroutedandlS8<:\nd

E1ectricalsystem Boll

16tnslnlmenb checkandreplacemenl 5 Unoc< .... II'.-~ .. coDle,.~ rtr.g 1'omtho'Ufctlho ... ,,.,,,,..,,tCl,,.' ''' :OOUn'::!'::o":",=~Ir:!:t'l1 ,ho

--. ....,.

_ _. . -_ __

:-:'-I1~~<'<JN'::~:ff=":=1.:

7W;!/Idr . ...

~caDle I'omlt . ~.)an
"""""e i, f,om '~e bil<e. ""'' '11 ,!I. "or""", • RouI • .,....-COff6O;"Y.....:r ....... _ ... i11 .-..g!1Jklel o) 'C"""*",",,coDkl UPl><" """'Dtho

;2E-"=::::: "-''!'!!''''''==~~

:~.-=~. ;~!:,~ =::r'~",:~~'o ,

---

2 fWnoV11lho .... """"""""" ... (SK1.",,5!

J OnUSZRSliOB1_ B2 _.,..",.,... • (.OVOt'.r>d

lho""' ..... _"'""'the'e ... _ _ 1ho""""'._ t....

nutI~

'ho"""",t;ngbtoel<e' _ ' _ o I I ' . brock.' . Tum' ... ~.,tnpknobanti·

8- 12 Electrical system

c;:Ioo;:t<wIM.-w;I_~ffomlhllfmntolthe c:IuIt_.~thItfteeSC<ewsonrhe~

01 tM elult .. which MCUre tll
acr.wI MCUMg IhIIspeedomet... torhe back OCMIi"andlift thllspeedomet ... out . On all otM< moo.l., ,,,",ovm tM sing" sc,ew s..:u,'ng Ihelnst'um..,. cluster ,ear cover and r..-r"lQ\ltl tM cover t_ ijlustralionl ~t"'nutsecu1ngrhespeedomete<'o tMbrackataodlih~ol!'Mbracket.fIOllng

I>DwiM IIfTI8II lug localU In tll
KfewMCWJ'lglhecasing and withdraw t... speeclomet.,trom tlloldeq t_ iII.,.trI Uonl lll.tDa

""'b.""'17.'s)

5 ....\aIMionllthS_oIremovsI.MaM ~sd~~lIcomoctly.nd54CUraly

Taehometer II FntCheCk altllewWlngin IhetacllOmSte< cif"cu;'!Of faub~ ... the wri"Ig
Ihlllueltaokt-Chapi.3).DisconnIIctIhll

_

..... ffomlhllprimaryeiraJittem.-on

IhIIlgniIioncoiflor"""'1>n:f4~.Tum t"'igniIIon.~ON .Connect"'''''''''tsd

jumperwlrsb
~:-a::~~~'7orcyc1etoa

10 0"1 all Olhsrmodels. ren>ovethe alngle Krew .... uring \he j""lIUITIenl elust.. r_ COVM_r...-eIhllCOYel" {_lIIuItration

:!;~I':.eo;:;:'~":Ck::'~~~I!:::: br..:ket,fIOHng I>DWlhe ""'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,eWSand
Replacement

wiles.c .. ~uIlYflOtingtheposltlonoleao;h

8~ 1hII""tn.menlc:iuIt_{$scIionlSl

--.

o;sconnscl'. . . .h'f,llewiringconnsclOf bet_'M Ischomelerwinng and the w'"*'lllightpenel~

' O"IUSZR550B l andB2mode1s._ 1hS_I*:UIIngIhS_CO¥fIr...:!"""""'" 1hII_.Removelhenuts54Curinglhe mounting bracket and remove the brltCket Tum the OOOrnfIt.. trip knolJ anli-clockwise Ind 'omDVI II from the front 01 the clu.ter. R,,",ovto.ha tacl>ome tllf wiring $Crew, mnd

::t::~~~t::e~ b..:koftMclusterwtlfchsecu,elhe iront O<MIi"andr...-eihelron.O<MIi".RemcMI'''' ..::rawasecurlngrhet..:hometerto theback CO¥fIr_lifIlhlltaCh:ImIII.cut.

wila.A1IO
~'~-=I:!:.t~!he

, _ 01 , _

...

Malee .... the wires 11ft COO..:liy arid

12 AomDvetlM seat (see Chapter 7). Tract t he luslle.elsendefwiriJ\g'romthe~

ot the fuet tank and "i$ConnllCtll atlh, coon..:ta< (e lank mounting boilS _ralse the lank at lhe ''''''. Of ,...-e the tank Ia< Improve<:l access If requlre<:l Chapt_3l t_illuslnlllonl.

18.t 2D1Konnaclthefuslle..... 1sndsr wiring connec:tor Isn"owed)

Electrical system 8- 13

13 Connect an insulated jumper wire btltw ....n the white/y~"'w and black/yellow termiMls on the wiring loom side 01 the connec!or.WoththelgnilionswI!d>edON,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"""SUfflchecl
""uge is faulty,the entire Iachometer must btl

-~

.

17 ::'S:~:c=tmingUght ~ Instrument bulbs ' To re~DC' the in.trument Il lumination bulbs, remov.thft f. levantin.trum. nt(..... Section 16). Gentt)'punthebuIb/IoIderOUlot theinst"""""'t, then pull the bulb out Of the

~\~i~~~~~'a~~~~ lntotheInS1f\lmef'll, then nstaHthelnstrumen1 back Into the casing Or the casing onto the Imtrument (see Section 16).

Warning bulbs

~RT5~~~e.: :~m~I~=,t ::n~!

~:~~v':~~e c~~~lrerC~S:, ~:I~~e t ~Ie~~e.:; bu lbhokleroutolthebacl
8 jromthepanet ..

8- 14 Electrical system

come on when the ignilion is torned on. check ttlebulb(seeSectionl1jandfuS8(SH SectionS) 3 The oil pressure sw~cll is screwed into the S
~~o~=~K~"':':o~~~~ the pulse gen ...atQf ass&mbly COl .... 10< ~,Remove tr.e screw (whe<e fitted) aod detach the witing connectQf lrom the s ..... tch

:~~':!~:c~~=~'=(~~ watT'ling light""""'" on. If the t;ght comes on, theswitchisdelectlveandmustberepaoe
5 II the waming lighl comes on whilst tr.e IMIQIMis runolng.yel the oil Pfessureis satislactory. remove th" wir"lr"m th" "II

6 Detach the wlrlno connector Irom the switch (SM illustration). 9 Unscrew the oil pres""re switch and withdmwrt lromthll sumPQfcranl
Installation IO Appty a suitable s ilicone sealant (Kawasaki Bond Of equivaient) t" the threads "I the switch. thflninstall rt in the crankca ... and lighten ~tGthe t Ofqoesell inO speclfieda l

~7 ~~si'=I~': UK

ZRSSO

B4

mDdel s ,instailthllpols e o~atQfassembly

us ing a new gasket and Hghten the boItssecurety 12 Fill the engine with Ihe COfr6C1type and quanuty of oil as described inCllapter t COl....

Note : TO prtIV
pr8SS<Xe sw~ch . W~hthe""'rede tache<.fand

Check

the lgnitlDn switched ON the light shDuldbe out. If it is iliumiMte<.f. the wire belween the s ..... tch aod instrument clust ... must be

1 Remo.e Ihe two s Craws securing the ~igOtrimt"the headlightshell,and"" ... the rim out 01 1he shell C_ illuslratlons7.1.

earthlld(groundlld)atsomepoitrt.lt!hewiriog 15(1000. thesw~ch must be assume<.f faul ty andreplBce<.f.

Removal 6 DSe<.f

:~kblj:~~~~;!~lono\~~s~:c'h~ :"ne<:trtatthllconnectormlheheadtight 2 Usirlg an ohmmeter Of a continuity tester. chack the continuity Dithll <:<>nnecIOftllm1ina1 pa l~ (s"... th e wlringdlggrem3attheer>dol

this Chaptetj , Contmuity shoukl exist betweero the terminals """"""te<.f by a sDlid ~"" on IhII d la!¥amwhen theswitch lsmthelndlcate<.f position 3 H the.w~cll failsany"l 1hetest • . r eplac e ~ .

Removal 4 RmnDve the instrun>ent clost&r(Sectiont51

5 RemDvethe hafidlebars(see Chapter S). /I Trace the ignition switch wiring and disconnect~at lheconnectOf(seeStep I). 7 Slacken the lork clamp bolts in the t"p yoke. tlleo remove1he steering stem bolt and

;~~el't~t:r:~~~~:. ign ition switch from the top yoke (see itluslralioo). In 1hefMKl1lhat special security boltsha.e be&nused.whic/lha.eshear· o ll heads, their he9dsmust b8 drilled 011

InstallatIon 9 Install the switdlontothe top yoke. Usino

new special To<x bolts. tighteo th&m until

=:~ooI==:. thebolthe9d,Of 10 The rernairder01 installation is the rowerse 01 rernoval. roghten the st_ing s tem bolt and the lork clamp bolts io the lOP yoke to the tOfq""settings specilied at the beginnino "I ChapterS. Make Sure a ll wiring is co
20 Handlebar switcheS' check

~

:Iii 1 Generally speakino. th" switch .... ara ,~andt,oubIe- fr ..... M""ttroubles.when they do occur. are caused by dirty or corrocledcontacts.butwearandbreakaOe,,1 integ harness 01 the s witch In question back to Its connectors and

Electrical system 8-1 5

disconnect them. The connectors located be low the luel tank . Remove the tank lor access (see Chapter 3). 4 Using the ohmmeter or test light. checklof

~:~i;~!ty ~~we: tt;~:::i~S ~~!~:~~~ positions (l9swilchoff - nocoot inuity. swilch on-cootinuity) (see the wiringdiagtllms allhe end 01 this Chapter). 5 lithe coolinuitycheck indicalesa problem exists. reler 10 Sactioo 2t, remove the switch and spray the switch conlacts wilh electrical contact cleaner. II they are accessible, Ihe conlactscanbescrapedc~anwithaknifeor

polished with crocus cloth. II switch components are damaged or broken, it will be obvrns when the switch is disassembled

lUei tank (see Ill ustraUon). Remove the lank lor access (see Chapler3). Work back along the harnes$,lreeing illrom all the relevant

7 Remove Ihe choke cablelrom the switch (see Chapter3 - this procedure incorporates switchremovaQ

clipsandtles,wh i lstnoting~scorrectrouting

Installation

2 Disconnect Ihe Iwo wires from the brake light switch (see iIIustralion 14.5} 3 Remove the Ih r Otl~ cables from the switch (seeChapler3- thisprOCedure inC
8 Installation is the reverse 01 removal. Make sure the localing pin In the front half 01 the switch fils Into ho le in the front 01 the handlebar. Refer to Chapter 3 for installation ofthechokecab~

22 Neutral switch - check ,

removal and installation

Check Left-hand handlebar switch

1 II the switch is to be removed from the bike. ,ather than iust displaced Irom the handlebar. Irace the wiring harness back from the switch to the wiring connectors end disconnect them. Theconneclors are located below the

them: the connectors are located below the luel tank (see illustration). Remove the lank lor access (see Chapter 3). Work back along Iheharness. Ireeing it from all Iherelevant clips and ties. whilst noting rts correct routing. 6 Disconnect Iha clutch switch wiring conneclor (see illuslration 24.2)

1 8elorecheckingtheelectricalcircuit.check Ihe bulb (sea Section 17)andluse(see Sachon5). 2 The switch is located in the Hlft-hand side of Ihe crankcase. behind the engine sprocket cover. Unscrewthegearchange linkoge arm pinch boll end remove lhe arm Irom the shaft. notinganyallgnment marks {seeill uslraliOll) If no marks are visible. make your own before removing the arm so thol it can be correctly aligned with the shaft on insta li atiO!l. Unscrew the bolts securing the engine sprocket cover to the crankcase and remove the cover (see illustra ti ons). DetaCh the wiring connector

22.20 Removelhe pinch bolt and slide Ihe armofl the shalt

22..2bEnglne sprocketcoverbolls (orrowed)-550models

22.2cEngine sprockelcoverbolls (arrowed)-750 models

21 Handlebar switches removal aoo installation

~ :~f~~v:~itch "

Right-hand handlebar switch Removal

is 10 be removed from the bike. rather Ihan iust displaced Irom the handlebar. lrace Ihewiring harness back from the switch

10 the wiring connecto rs and disconnect

8

8· 16 Electrical system

22.7Disconnecttheneolral swilchwiringconneclor from theneutraf switch (see IIfustration22.7). Make sure the transmission isin neutral 3 With l heconnectord isconnecl edan.dlf1.e ignition sw~ct1ed ON. the neutral light should be 001. If nol , l he wire belween IheConnector and Instrument cluster must be earthed (grounded) at some point 4 Using an ohmmeter or co nti nuUy tester, check for continuity between the switch and the crankcase. With the transmission In I'>8Utral,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 theconta<:t on the neutral switch

Removal 6 Unscrew the gearchange linkage armpiflCh bolt end remove the arm Irom the shall, noling any alignmenl marks (see Illustration 22.2a) II no marks are visible. make your own before removing the erm so that il can be correctly a lignedw~h theshallon installalion. Unscrew the eng ine sprocket CO\'er boits, and remove thecover (seeillustrations22.2bandc) 7 Delac h Ihe wi ring connector Irom the neutrel switch (see illustration). Make sure the transmission is in neutral 8 Unscrew the switch and remove it.

Installation 9 Instellthe sw itch and tighten il to the specifiedtorql.le

23,2 Disconnect the sidestand swilchwiring connecto<"

10 Reconnect the switch w iring connector (see illustration 22,7) . 11 Check the operation of the neutral light 12 Install the sprocket cover and the gearchange linkage arm, al igning the mari<s made on removal

Chapter. ~ all components ate good, check the wiri ng betwf!8l1 the various components (see the wiringdiagrams at the end 01 this bookj.

=

SidflSlflndswllchlroubles may be caused by a sl/cklng switch plunger due 10 Ihe ingress of road dir1. peel back the rubber gaiter and spray the ~~= wilh a wat.r dispersant •

HIN

23 Sidestandswitch checkandreplacemenl

Check 1 The sidesland switch is mounted on the Iramejust ahead 01 the sklestand pivot {see Illustration 23.8). The switch is par1 0 / l he salety circuit which prevents or SlapS the engine running II the transmission is in gear whilst the sidestand is down. and pre'lents the engine from star1ing if the transmission Is In gear unless the sidestand is uP. and unless the clutch is pu lled in. Before checking the electrical circuil, check the luse (see Section 5j 2 Unscrew the gearchange linkage arm pinch bo lt and remove Ihe arm from the shall . noting any alignment mari<s (see illustration 22.2a).llnomari<s arevisible,makayourown belore removing the arm so that il can be correctly aligned with the shall on installation Unscrew the bo lt s securing the engine sprocket cover to the crankcase and remove the cover (see illustrations 22.2b or c). Trace the w iring bac k Irom the switch to lis connector and disconnect ~ (see Illustration). 3 Check the operaIion 01 the switch using an ohmmeter or continuity test light. Connect the meter to the green/wh ite and black/ye llow wires on the switch side of the connector With the sidestand up there should be continu it y (zero resistance) between the terminals. and with the sta nd down there should 00 no continuily Qnfinite resistance). 4 lithe switch does not perlormas expecled. il is delective and muSI be replaced. 5 li the swnch isQOOd,checkthejunction box and olhercomponentS in the starter circun as described in th8 relevanl sections 01 this

Replacement 6 Thesidestand switch is mounted on the lrame just ahead 0 / the sidestand pivot. Unscrew the gearchange linkage arm pinch boll and remove the arm Irom the shalt. noting any alignment marks (see illustration 22.2a). II no marks 3/8 visible, make your own belore removing the arm so that it can be correctly aligned wnh the shalt on installation. Unscrew the bolts securing the eng ine sprocket cover to the crankcase and re<nove tl\e cover (see illustrations 22.2b or c). 1 Trace the wiring back Irom the swilch to its connector arid disconnect ~ (see illustration 23.2) . Work back along the switch wiring. frooingitfromanyr~evanlre teiningclip$and

ties, noting Its correct routing. 8 Unscrew the two bolts securing the switch to thelrame (see illustration).

Electrical system 8- 17 5 Installation is Ihe reverse of removal. The switchisn'ladjuslabie.

Check

9 Fit the rt9wswilch to the frame and install the retaining screws, tightening them sacurely 10 Make sure the wi.ing iscorrectly.outed up 10 Ihe connector and retained by all the nocessary c/ipsand ties, II Reconnect the wiring cOlllleClo. and check lhe operalion of lhe sidestand swilch,

1 Remove the seat (see Chapter 7) 2 The Junction box contains Ihe starter circuit retay, the diodes, and on US models Ihe head llghl relay, 3$ well as Ihe fusebox. The startercircuilreiayanddiodesatepartolthe safety c ircuil which prevents o. slops the engine running if Ihe transmission is in gear whilst the sidestar.d is down,aod prevents the engine from starting il Ihe transmissfon is in gear unless the sidestand is UP. and unless the ciutch is pu lled In. Slide the junClion box OUIof ils ho lder and disconnect the wiring conneclors (see Illustration) 3 Using an ohmmeleror conlinuitytester aod a !Z V battery with aux iliary leads, connect the meter probes and Ihe ballery ieads (when

specified} to the relay terminals on the lunctionboxconnectorsaSindicated(see illustrations). Use aoohmmeleror conlinuity tester to check the diodes. II the resu lts achieved after allle(minal pairs have been tested as ind icated do '101 agree w ith the resuks spec~iedinthe tables, lhejunctionbo~ isprobablylauUy -haveyourllndings confirmedbyaKawasakidea~beforebuyi"9

areplacemenl

2
Check I The clulCh switch is siluated on the base 01 lheclutchle'lerbracket. The switch Is pari 01 the salety ci.cu~ which prevents or stops the enginerulllling II lhetransmission Is in gea. whilst the sidestand is down. and prevents the englnelromslartlngil lhet.ansmissionisin gear unless the sidestand is up, and unless lheclutch is pulled In 2 To check the switch,disconnoctlhe wiring connectorlrom the switch (see illustration). Connect the probas 01 an ohmmeter or a continuity test light to the black and blacklye llow wire term inals on the switch. With the clutch lever pul led in,lhereshould ba continuity (zero resistance). With the clutch leverout,the,eshouldbanoconlinuily Onfinite resistance). Now connect the meier probes between lhe black and blacklred wire tenninals on the switch. With the clutch lever pu lled In, there should banoconlinuily (infinite resislance). With lheclutch leveroul. lhereshoukl be contil1\Jity (no resistance). 3111heswitchlsgood,checkthejunctionbox andotlleorcomponentsinlheslartercircurtes described In Ihe relevant sections 01 this Chapter. Ifall components ere good,check Ihe wiring batween the various components (see tha wiring diagrams at the end 01 this

bookl. Replacement 4 Disconnect the wiring conneclor from Ihe clutchswitch (seelllustretion24.2j, Unscrew thelwo screws securing the switch to the bottom ol lhe clutch lever Ix3cket and remove

I\eIoyNpooctior>(withIhlNnooy_odi

-

M....

::1IoIor

......,

c--.....

11 - 13

25.38 Junction

bo~

tests - ZR550 81 to B5 end ZR750 CliO C4 models

D/ode eheck s 9tol3(IJSfCenedaonly}

810 13 (lJS/Canadll only) 121014

151014 161014

Wllenleslingdiodes,lheres1slancereadingsh(luldbe lowmonedirection(oonlinuity)and loo times as high (no continuity) when the meter probes are reversed. A diode which indi(;alfJ$ high orlowroodi~m eachdireclion/lasfailed.

8

8- 18 Electrical system

26 Fuel level sencIer-

check and replacement Warning: Petro/(ga s olinaJ is .... trema ty flammabla. so taka a~tra precaution. whan you worll on-.typart of tlla fuel syslem.Oon'lsmoka or llllow_flames

A 1 •

orbanlllghlbuUH"""r'hewor1r""",. " nd

don" wo,*In " /Jaraga wharaa natural /J8.·typeappllan<; a l.presant. lf y ousplll

any fua/on your skin, rin.a l, off immfHIill t ely with SOIIp and w ll tar. Wha n you perform a ny kind of worll on th. f ual .ystam...........fetygla _ .ndha ... . flra

... linI}"ul$/l.,. suJIablaloraclaNBtypa frr. (fIammablaliquldsJonlland.

Check 1 Remove the soat (seeCha!:>ter 7). Tr""" the

~~=:~:=~~~~z

"""nacto!" (remove the tan ~ mountino bo~s and noi .... the tank at I!>er...... 0< remove ti>e tan k '0' improved access "requlred- see Chapter3) (_ '''ustratlonl6.12) 2 Usi ng so ohmmetar sat to oIlms ~ tOO

=:;":::e~ ~ co!:ort.7'rn:\~ resistan<;e readino with the tan k empty and full. Compa<ethe readings with !hose

'---- ---=-::-c===::-o=======-- '--25.3b Junctlonbo~t8St.

0i0<M clled!s 91013(USlCBnadllonIyj

ZR550B6,ZR750C5andOl models 810 13 (US1Canada onI)i) 15/0 14 12/014 16/014

~sted

trom I!>em'I!er thtl tank (see Steps 4...aod 5 below) and. WIth connected above. maroally mova the 'Ioat up and down to emulate the ditfereotpositions t_ iMustratlons l. 3 II thtl ,eadingstal<endiff... to thoSlllisted in

~lltStjngdiodn.t/)fJ~/BfJC8rNdingY>t>uldbelowinonedireclion(con'inulty)IJIId"'"

thtlspeciflcat k>n5.~thtlsender.

limesasfligh(nocootinuily)wllanlJl8malerprobe$arerftWHS¥.J.AdiockIw/llcll/ndica'ltShJgh orlowreM1ingsinew;hdinK;/ionhat;faifed.

Replacement 4 o..ain a nd r"mov" Ih .. fuel tank

4 If I!>e 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
disconnect the wiring connecto<s (saa

tanl
~:;r::~t!~;.::: :..e=..~x and 7 tnstai thtlseat (see Chapter 7)

6 Instattthe senOe
thegasketJsed. proeess.using a newgasket {_

lIIustMion).

Electrical system 8- 19

'r7.3b Carburettor temperature sensor (aITDwed}

Sensors

Check 1 The carburettor heater system lilled to UKZR550 94, B5 and B6models, and to UK ZR750 C3, C4, C5 and Dl nwdels incorporales a h9aler unil in each carbure1tor body, an atmospheric temperature sensor in 1119 airlilter housing and a relay. TheZfl750C3 andC4 models also have an oil lernpefalure sensor and relay , and ZA550 B5 and B6 and Zfl750 C5 and Dl modefs have a carbureltor temperaturtlsensorandasyslerncOl'ltrolunil. Heater unit 2 To chock 1119 heater un~ in thtl carburtltlor, disconnect the wi ring connector Irom Ihtl healer being leslad and 1119 blacklyellowwire "om 1119 earth terminal. Using a mu~imeter set 10 the ohms x 10 scale, louchthe positWe{+) probe to thtl heater ttorminal andlhe ntogalive H p!'obe to the earth terminal on Ihe carburettorbody. If Ihe reading oblalned is 001 wilhin lhe range specilied at 1119 beginning of lhe Ct1apter, replace lhehealer. Repeal the Check lor lhe remairnng heaters.

3 To check the atmospheric temperature stlnsor, the oillemperatu re sensor and t he carburettortemperature sensor, disconnecl the wiling cooneclor and IJflSCtew 1119 sensor. The atmospheric temperature sensor is Ihreaded into the froot of the air fi lter housing (see illuslration) ,the oil temperature sensor is threaded into Ih e crankcase below the pulse generator asstlmbly COVtlr, and the carburettor lemperature sensor i$ th readed into the 00. 2 carburettorln placeol one of the joining bracket SCfewS (see Illustration). 4 Fill a small healproofcontainer with water (for th9 atmospheric and cafburet10r sensors) or oil (lor the oil ttompOl"lltulll sensorjand place

tem peratures required lor testinglhe sensor are not Ngh, SO avoid applying excessive heal

~ :~':::I~ ':'cisa";~~! ~:o~~:ez Ll.l.

porsonal injury, 5 Referring 10 the specilica tions al the beginning 01 Ihe Chapter for the Stlnsor being lested,chtockwh9lher!heresistancereading

~onastove.Usinganohmmeter,coonoctthe

positive (+) probe 01 tlIe meter to the terminal on the sensor, and Ihe ntogative (-) probe to Ihtl body 01 Ihesensor. Using some wire or olhersupport suspend the sensor in lhewaler or oil SO lhaljust 1119 sensing portion and the threads are submerged. Also place a thermomeler capable 01 reading temperatures upto5O"Cinth9waleroroilso lhat~ sbulbls

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 .. tempe
Relay .. TD check tM atmospheric t.. mperatur.. ""SO< and Dil I"mperatu,,, '''lay, discoonec:t Ihe wiring connector f,om Ih" reiayandidentifylhet"""inaI......oo..rswhicl1 $l>QlJldbllmarklldontheMlay termina/a. The retay ~ mounted behind Ihe ~ght · hand sid"

' ' 'SO<

_

J

4

panel on 550 m<>de/s,and underlhe fuel tank behind IhII r"OulatDl"'rlllClifie< on 750 mDdllls 1_ "lu s~:n . h.nd bl ·Rerr>Dve1he

siOepanel(eeeChaptElf7)orthll 'ueltank(eee Chapt... 31 for """""" 7 Connect Ihe probSitive(+)wiNltD term1nal 1 and tha l'>&gal1ve H wl ' e 10 terminal 2 (He lIIus tr. tlon sJ. The meter shDoldshowconlinuily(zerDraslstanc ..)lor th"atmDspherlc t"mpe'8Iu'eSGnsor, Dr rIO continu ity (infinite resistance) ID' the DII tampe
conti nuity (inllnit" resislallCe) IDr Ihe lIIrnc>sphericlemp..-atura S8OSl>l", orconlinuily (zerD resistance) 'Dr Ihe!>ll te mperalura Hnsor. If Ihe ' &ad lngs Dbtalrl
~

mountl!dbeilindlh .. ignihoncontrolunitDn 550 mDdllls (nece ssitating it. ,ernoval· ."" Chapt.. , 4) and bithlnd tha left-hand sid
I(W/G)

SlBK)

Replacement 1(1 The carbur.. \lor healer s yst&m li\ll!d 10 UK ZR550 84 , 85and B6 mDde ls, and tD UK ZR750 C3, C4. C5 and 01 mDdels incorpc>ralesa heat ... unit in each cart:uettor bor in Ih .. alrfjlterhoos;ng and8 ,etay.ZR750C3 and C4 modaIs al60haV
2(0)

(unitkO) TMIIIf(+)L8IdConntdion

,

1

2

(WfG)

(G)

3

"

(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, an
Apply a silicone searant to the (hreads Of the oil ternperature sen!lOl".

28 Hom -checkandreplacement ~

~

app/y battery voltage directly to the terminals on the hom. H Ihe hom soundS. check the switch Is" Seclion 2t) and Ihe wIring be\ween the switch and the horn lsee the wiring~ms8tlllfleodol th is CI\apler).

3 II the hom daMn'l sour.d. replace~.

Rep/aceme"t

2 Unplug the wiriog connectors from lhe hom I... IIlu.lt,tlon) . U~ng two jumper wtres,

4 7l>Ahom Os mounted in f,ont o/the eogina below the steering head. 5 LIflpl~ the wifing connectors /rom the hom (... llIustratlon28.2).lhIIn u"'ICff"Nthe~ securing lhe hom bO"ackat and remova lhe hom Irom the bike I_Illustration).

28.2 Disconnecl the horn wiringeonneciOB

28.5 The hom bracket is MCUI"8d by two bolts lalTOWed)

Chock t The hom ismounled in Ironl of lhe engine beIowthest~he8d

thef~tankb8hindlheregulalor/recIif"" on

750models ls_IMustralions). Removethe side potnel lsee CI\apt"7) or lhe fuel lank (see Chapler 3) for accns. Di$Conm.ct Ihe relay wl~ngconnectorandrelTlOlletherelaYI_

illustration). 14 The system control vnit is mounted beNndtheq,itionCOl"ltroiunit on 550 mod&ls aoo behind the lelt·hand s ide panel 00 750 models Is_ IlIu.trstlons). Remove Ih' IQni1Ion control unit (see c;nap.er 4)or the side panel lsee CI\apIer 7). Oiscoonecttllflwirirog It the connector and pull Ih,unil and ils

~~~::;:rooolli:St~~Ugsol Ma~ e

removal. !IIl.e all wiring connectors ",e s ecure

8

8- 22 Electrical system

29.4 Star1errelaytnt .... t ... Wandbiltt..-y(6)COfV>Ktlons 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$e(We5«:1ion 5). 2 The ltarter re!ay G located behind the 1eIthandsi(lepa...... F\en'I
Cl:N8Ionthestartermoloriead.thenunscrew the nut securing the start8f mo1or lead to its terminal and disconnect the lead (see illustr~tion) . MakIng sure thai the di$COM8Cted ~ is wejl cIea( 01 ~s lefffIinal. sw~ch the igniHon ON and ensure the engil"H! kill switch Is In the RUN pos ition. the lransmlssionlslnr.eutraiandtheclutch pulled ~~;:.ssthestarterswltch.Therelay

3 li the relay doesn't click. switch 011 the igniti(ln and remove the relay as d!tscribad below; test it as loIIows.

~,::;::~r=e:llr=-the.:~ it across t.... reiay·. lIarter moIor and bilttery

click and the mu ltlmeler read 0 ohms (continuity). II this Is Ihe case the ralay Is proved good. li the ratay does nol dick when battery voll age I. applied and indicaleano coolinuity(lnlinileresistance)acrossilS

detach the leads !aee illustration). Remove lheretaywilh ilsrubbet" st_tromlts mounting tugs on the trame.

II Installation is the reverse of removal. ensuring the terminal sc.ews a.e securely tightened. Connect the negaHva!-) le.ad !aSI when,econnectir.g the bilttert

30

Starter motor removal and installat ion

terminala.~ Is'aultyandmustberepiaced.

5 II thto relay Is good. cl>eck for battery voltage betwe8fl the yeIIow/red wire and the bIac~low wire when the starter bt.mon Is pre5Sed. Chitck the OIher components in the starter circuit as described in the relevant sectIons of lhis Chapter. II aI components are good. check the wiring between the variOlJs componenls (see the wiring diaglllms at the end 01 thIS book).

Replacement 6 Remova the seat and the lell-hand side panel (see Chapter 7). 7 Disconnect the battery terminals. remembering 10 disconnect the negative H terrninalftrSt. BOisconnecIthereiaywiringconnector.then unscrew the two I\t.Its securing the stGrter motor and batt..-y leads to the relay and

Removal 1 RemoYe the seat (see Chapter 1). DiIoomectthebiltterynegativel-)lead. 2 On 550 models. unscrew the two bolls securing the starter motor top cover and ~II 011 lhe cover (see illu stration) . Slack.., lhe upper starter motor IllOIJnting bolt. than r8fTlOvelheklwerCOller (s&&illu stra!lonl . 3 On 750 models. unsc,ew thegearchange linkage arm pinch bolt and remove the arm Irom the shaf\. not ing any alignmenl marks (see illustration 22.2a) . If no marks are visible. make your own before removing the arm IOlhat ~canbecorrer;:tlyallgned withlhe malt on Installation. Unscrew the bolls securing the eogine sprockel cov.rto the cr,nI
Electrical system 8-23

30.5 Un....... w the mounting bolt •. . secllrirlglheslartermolorlopcover,no!lng how Ihe co llar and rubber damper ti l . and rEIITIOve It\e cover I,ee illustration). 4 Peel back Ihe ruboercover and unscrew lhenutsecurioglhellartercablelolhemolor I _ Illustration). 5 UnscrewUlelwobollslWlCU!lngUleslart1lf moIortothecrankcase j_Wlustratlon). 6 Slide ttle starter motor OUt from the crankcase and remove it from the machine lsee iNustralion). 7 RemoYetheQ-mgon theentl of the starter motor and diIcsrd ~:a rwwonemu$t beUHd.

10 Inllllil the starler motor bolts. On S50 models. Ilghtllfl only the lower boll . leaving the upper one ,lack lor the lower COVef. On 750 models. tlghlen both boilS 10 the lorq.... setlingspecil iedallhebeginnirlgol theO\apler. 11 Connect the slarter cable to the motor and sectlf81t wI,h the nut Isee IHul tral10n 30.4). Make ...... the rubber cover is COfTectiy seatedfNerlhet~.

startefmolorbolt )seefllu stratlon30.2b) Tlghl8ll the bolt to secure the COVIlf. Install the upperCOVIIr andtighlen its bolts. 13 On 7S0 models. install the top cover. making sure the rubber damper and eoHar are corr.ctlytiUed,theninslalithebolta (se. IIIustrallon30.3). lnslalllhespfocketcover andtheg&archangeWlkagearm.aligrwlglhe marb made PfeYiously. and lighlen the pinch boItseeur.ly (see illusiTation).

12 On550modeIs,insl8ltheIowerCOYel"so thallhelronl mounting fits around lheupper

inslall lhe Mat.

14 ConnectlhltbauerynegalMlHteadand

Installation 8 Inllan a new o-nng on lhe end of the starter motor and ensure It Is seated In Its groove lsee Illustration). AW"I a smear 01 engine oil 10lheO-ring toBidln$tallation.Makesurethat thematingsurlllCftbelweenlheslartermotor mounllng poinlSand lhe erankcase are clean to 8flSUlI a good earth (ground). 9 Manoeuvre the molor Into position and $Iideit lnIOlhecrankcase j ... illustration 30.6). Enaure lhallhe starter motor teeth mesh correctly wIth those 01 the starter idlWreductiongeflf.

8 3O.t3 In. ...lltheengines.prock. t cover

8- 24 Electrical system

7!iOmodeIs.rtor'J'IOVI thegplale.notillg _tIleI"lOlCl"l in ~perlmelerlocat" overlhe

Disassembly l R~tlle. tarl"'mo1O«_~ion3O]

2. Not. the .'Ignmftnt

the maO'Ihoo.Itingandlhe rront .-.
....

~to

ma'~ , ~ tw ....,

.... 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,""""'"

.......... .naft0<1rcm~1he,...00YW.

=:tlo:.~ Onlnu~~~':,IIada..:~ro·Cl~~ and C3 modets. ,ema.. thl I>rushplale assembly and termlnll bolt f,om the main houSlng.OnattOI""'~".'erno .. thl ~1 •• u.ernbty.ndl"""""'boIIlrom ,....,..._ I_illwtnodon) . 7 LlItIhe_springsandllidllhe_

4 ~tllef,on lcov ...

.,..,tromtheir~notong_tMylit.

_tromlhestarlermolorl_illuslrations!.

~~~~~.~~he~'asco": fromlhemotoralon<,jwith~Q-ring.Ooscard

::!."':..~":...":. ::1'::: aIon<,jwlth

1fom1Ilemo1O< flSl).ring. DIsc.-d the O.mg as a

new one mu.t be uMd. On 550 modef. '~lhe washer($j f rom lhe"ontendQ/the

... met"".haf1andthe ...lprotecto
In this Chapl... ·• SpeclflcalHlt1S I' " lIIutl, . tlon j.Hanyollhebfu...... .... w Ofn beyondlhoes.vic. IImit. ,eplecethl tJrulh .......tlIywilh • .-ont. n l h e _ ... noIwom '~. r"IOfCtaci<"".~. Ofotl\enoMe~.tfMymaybe"""- .

Also chick thebruah 1If>rinos. making """ : ' : : : ! t a fi,mpt'.lureonlhebtUlh

' Inspect t/lecomrnulaton I_ Wlulu allonl. Tnt oornmuIMOO",*,bedMnedandpohhedwith Ctocwcloth.buldono' .... sandpaperOf

..._ _ ----......

Electrical system 8- 25 OIhIrI.AIIo.chlcktorCOflIinuity~1he

commt./WOO"t.1Iandlhearmat..... """ft l_ iIIuIlrlllon). n.."lhouIdbenocont inu!ty

~hI~It~:::-''::

0IhIrwiM. Ihetwma!I.Q is defective.

~~t:"'~.~:""~

conlinulty (zero resistance). ChIcle tor contlnuitybel_thlterminalboltaodlhl houtIng(Whln~.The<elhouldbi

61T1et'yP6l*'.Alterclunlng.wlpea w ayaoy fflidue with" cloth lOaIced in eIeclrk:aI .....1.... clNnerOfderlaU..e d _ . Clean

~IM~~::== _COfI'lI*"ItIOlhespecillcations.1I1M c:ommut.,Of .... worn 10 beIow~ • ...,.,.;c., 1IrriIl,1he_..... muabl<ePaced. 10 u.ing an ohMmIter Of " continuity ' " t HghI,chlcktOfconUnuitybe_1he QCIIn'NJI.,ort.1l l _ iIIuItmionj.Continuity ~...u.1~8IChbarand"'otltWl

N>COfllinuityjinfonitlrMistance). 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 ~" lIIustratIO<\s) . Takeca, e not to damage the ~. OnUSZR7SOCt.C2andC3mode1s, Ir-' t hearmatl.reintothemain~.tIlen

Iocate thesprtngendsontotl>&bnJsIloIssolhat the br\J9.hes are pressed onto lheconvnutator On all models. check that each brush is SIlCU"8I)Ipressedagainst lhecorrwn,aatorbyits spr\r'Igand is lreetornove6asi/yinits_. 18 Fit a newO-.ing onto each endoT the mait1housing (_ iMust.ation).Onall e. cept USZA75{) Ct, C2 and C3 models, slide the hooJsjng over the armature. aligning the marl<s made on disassembty (see iltustrallon).On US ZR75{) Ct, C2 and C3 models. slide the shims overlhe"",.and of the armanJfe shaft. tl\enTrttheendcoveronto themainhousng. aligning the mar!<s made on disass.ernbty 19 On 550 modets.apply a smear oTorease to the lips 01 the I,ont WV&I" 0<1 seal. Fit the washer(sJ onto Ihe shaft and the seal protector onto the "ont cover. maki"lg sure that the tabs 00 the seal protQCto,k>cate corrQCtty (s. . Illustrallon). lostall the cover. aligning the

:~~a:t':\~;~" ~ ~~he~':'! snaft. t hen lit II>e 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 InstalleOtch between the perimeteroftheringgearandlhelrontctMll" 1_ lIIu$lm1lon). Fit Ihe "oot cover ooto the housing. aligning the lug on the inside of the mainhousingwithtlwl<">Otchinthepertmeter ofthe·nggear l_ iIIust.ation)

31 .19<1 Maka sure Ihe locallng pin IS In place ••

31.1ge ... lhenfitlhefrootcover, atlgnlng the lug (A) with the <">Otch(B)

20 On 550 rrtOdeIs, slide the k>ckwasl>er and a roew O-ring onto each of the Ioog bolts (see iNustration) .Onalmodels,checl< tlwlmarl<s

made 00 ............81 are ahgoed, then Ins ta~ the long bolts and tighten them se<:u.ely (see IlIust rat;on) .OnSSO model., make "me tf>e

Electrica( system 8- 27 7 Conna<::t a multlmelet' setto lheO-20 volts d<:s<:a~(vollme t e<)acrossthetermjnal.ol

IIJIII...... ~:!~~!~',j~7i~:e~J,~:e5i:~~~:

thebatte
readfngobtaioedat ~eSpeed-~shouIdbe

justuJ'lde
---=

L"--,-,,.,___ 31.2OaOnSSOmodels,do nOlI0<"1/8t ..... O-rlngandwashe
32 Charging system testing general information and precautions 1 If til" performance of the char\ling system ;ss.uspect. tile system DS a whole should be checked firSI. followed by le511n\l of Ihe individual components. Nole : Before beginni"9 thechecl<s. make sum ffIe barrery is fully chargtJdand rhar JJII system connecrions

""'clean and figh t 2 Checltlngthe OUlpul01 the charging syslern and Iha perl",m8nce 01 the various component. wilhin the charging syslem reqUiras lhe use 01 a multimeler Iwitllvolt8lle c ......ent and resistance cl>eclg 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 e<>nstanrl)' 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 sIIo<"I clrcuilin the witIng . Thorouglllyclleck the wiring betWMn the .arious components (seethe wiring diBgramsaltheendofthisbookj. 51! Ihe reading is below the specified amount. the lea kage ' ale Is sallslaclO<"y Disconnecllh .. m.. lerandreconnectthe negatiWl(-)kladtollleballery.tighleningrt ~=~=k thealtematoroUIPulas

___---'

8 Carry out the abo.etest wilh1llehlladlighl turned off and oole Ihe readings . On US!CanadalheheadOghlwireconneclormusl be delachedftom II>e back 01 the headlight unit to tum off the '-
en\lineand wa,mIt up tonormat operating temperatllfetller1stoplheer>gjoe

beforeremo.ing the arm so that ilcan be correctlyafignedwithlhe!lhaftooinstajlal;.,n Un"" ,ew Iha bolts secu'ing the engine sprockat cova. to lhe crankcue and remove the cover (see iflustration. 22.2b Of c) 10 Trace lhe afta.nalOf wiring Irom II>e base of the aftemalOfCOVw 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 Altemato<"wirI"1Iconnec\Of (arrowed) -7~ models

be left

Outpuftest Regulated output test

6 Remo.e 1IIe seal (..... Chapt"'7j. $tartlhe

8 33.3 Checking"'" charging system leakage rate. Connecttl>emetera.shown

8- 28 Electrical system

ll Stoptheeogine.thenconnectthemeter to another pair 01 yellow wires and repeat the test. Stop the engine then test acrosslhe remaining pair 01 yellow wires. II any 01 the Ihree readings are below the minimum specified. check lIIe stalor coil resistar.ce(see below). II the reedings are good. check Ihe reguiator(see Seclion 35).

Alternator s tator coil test 12 Unscrew lhe gearchange linkage arm pinch boll and remove the arm Irom the shall. nollnganyaJignmentrnarks (see Wlustration 22.2aJ. It no mart\ll\fe visible, make VOU" own belore removing the arm so Ihat it can be COfrectlyatignedwoththeshaltoninstalation Unscrew the boilS securing the engine sprocket cover to the crankcase and remove theco_ (_ lltustr&tions22.2borcl . 13 Trace lhe alternator wiring from the base ollheallemalorcov(Jran(!d iSC()M8Ct ilatthe conneclor(s) (see lliustrallons 33.9aor bl 14 Using mU ltimeter sel to the ohms x 1 sca le . checkther~tar.cebetw~eachot

the wires on the alternator side 01 U.e connector. taking . total 01 thrflfl readings (HfI illustration,. Aiso check for continuity between eadl terminel and &arth(ground). If lhe slator coil wMdinOS l\fe in good condition there should be the rHlslance specified betwflfln each 01 the terminals. and no continuity rllfiniteres<stance) between any of lhe lenninals.nd ground (earth). II not. the aitamalor stator coli aS$8lllbly is at fault and should be replaced. It the resislance readings are as specllle
34 Alternator removal and installation

~

~

Removal 1 UnllCfew the gearcnange linkage arrn pinch bol l and remove the arm trom the shaft. noIlnganyallgrvnent marb (seeitlustratlon 22b). II no!TWlfks are visible. make VOU" own

5 To remove ttle rotor Irom the snail il i. neoestary to use a rotor puiIer. The Kawasaki special l ools(pt. no. 57001-1099 for 550 mocIeIl. andpt. nos. 57(l()1-115 1 and 57(l()11216 lor 750 models), or a commercially available rOlor puller can btl used (mak ing sure It has theCOfrect thtead on It). Screw the pullltf Inlo Ihe rotor thread. and using the method employed aarlier to stop the rOlor fromtuming.tightentnepuleruntiltnerolor is cIispItIced from the shaft.

:.c:~=..::.:m':It~~:~ r~ ---A-~-'-"-"P -oo "-,-'"-d-."

=e:~!:"u:e~::= ~ ~:c':"~~ b';;l!kln~S":~~ :-,.=~--:::::~~ :.,c:;..~ot

~:~e:~i(=~I::ra~:'~~'o::~

t:;

Release lhewlring Irom any clips ortias 3 Unscrew the alternator COVItf retaining bolts and lift the covltfaway IrQrn the engine (see IlIulll1ltlon). The lIalorIs mounted Inside lhe cover. Remove the gasket and discard il ~tne twodowels lromeithertheCO\l8l'

Of the aankcase. ~ they are loose. 4 To r.....,.... the rotor bolt. the rOiOf rl1U$t be

corrosion free betw. .n Ihe

.._._n_'__.--,

L _ _""_M_"",, _~ _"_,

e TO remove tha

stalO' from the crankcase cover. unscrew the three bolls s&C uflng Ihe stator and Ihe screws securing the wiring clamp, Ihen remove the assembly from the CO\I8I'. l'IOIiog lhe routing of the wiring and how the rubber gronvnetfits (see Wlustration).

hekI~rolation.tfarotorhoidingstrapor

Installation

toot Is I'IOIlIIIaiIabIe.placetne transmission in gear and have an assistant apply the raarbnlke.Uoscrewtnebolt (seeillus\r1ltion) ,

7 Oe-grease Ihetape<e
notduatodamll~w;ringbelweenlhe

corv>ecfor....ocolls.

34.8 Stalorbolls (A),wIring damp screws (8)

Electrical system 8- 29

3<1.9 Install tI\e oover ",sin9 a newpsket

35. 1a Regulator/rectifIM wiring connector (8ITOWed) - later 550 models

35.1b Regulalor/reetillerwiringconnector (....owed) - 150 models

thai no melal obiects have attaehed thernsel'vesto the magnet on the inside 01 the

as shown in \he table (see ~Iuslr.llionl . li the readings do not compare closely with lhose shown in the accompanying table tile regulator/ reet". unil can be considered faully. Not.: The use 01 certain mulrimerers coo/d IHd fO Ia/se I"8Itding$ bfJing obl';n&d. Therefore, If Ihe eboo..., check shows lhe regu/frorlfllClilierunil lobe faulty talte the unif 10 a Kawesal
3 To lest tile regulator CircUli. three fully charged 12 V ben....'. each with a HI Of auxiliary leads. arid a lesllight ar.reqUlfed (see below). tI these are nol availab!e. earry out a charging system Iesl (see Section 33). II tile eondil ions arise from Ihat lesl Ihat Indicate a faulty regulator. take II to a Kaw/lS/lld dealer for furthe< testIng. Clues toa faul1yregulatorareconstanttybiowingbutbe. wllh brightness varying consld8fDbly wllh

rotor Ihenin$taI\he rOloronto the c:ranksnah.

tnst.u lhe rotor bolt .nd. ",sing the melhod employed on removal to Slop the rolor from turning, tIghten it to the lorQIHI selling specifiedallhebegiMingoltheChapier 8 InstaDlhestator into \hecover.aligninglhe lUbber WIring lI'onvnetwith the 9rOOlle in the cover. Apply a euitable non-pefmanent thread-loeking compo",nd to Ihe stator boll threads. then Install the bolts and lighten them to the speeified tOfQIHI setling. Apply a suitable sealant 10 the wiring grommet, lhefl installil intolheCUloutin lheCOYer.lnst.Nthe wWlngelampand MCureilwilh theserewl (see ~luslr8tlon 3<1,&). 9 Mak..... lhedowe/Sarelitled.theninsIaR thellllernalor COYer using • IMW gasket (see

oond/tiorlb8knl"fJpladngil

~

iIIuslration). TlQhlentheCOYerbo/ls~in

a cnss-CfOU S8QUIII'"ICe. t O Ae<:~tlhew¥lngat\heconnector(s),

making surelliscorrecl/yrouted.aodsecure it with any elips or lieS (see illustration s 33.108orb) I I Inslall the sproeket eover and the gearchangelever.al;gning themar.csmadeoo removal.

35 Regulator/rectifier unit check and replacement

Check l Theregulalor~islTlOl.Wltedbehindlhe

righi -hand side panel on early 550 models. below the ballery tray above thefronl of the swingarmonlater55Ornodeb.andunderlhe luettank on 150 models (see Illustr.tions 35.&0 and b) . Remove the right-hand side panel (see Chapter 1) or the fuetlank (see Chapter 3) as requifed. Trace the wiring from the regulalor/recll!ier unit and disconnect ~ al the eonneetor, or disconnect Ihe wiring conneetorfromtheunit , accordingtomodel (seeiNustratlons). 2 Totesllherectiliercit'c:ull.useamultimeter sel to tile appropriate resistance scale and check the resblanee between tile various terminillsof lheregutalor/recllfier cornectors

a

W SR S KlY

... , ,

,

·, ·,

··

" " "

Y! YI Yl

eo.......... .. _ r( +) to

~ A,edlnil

MoO •

"-

M_ r ( - ) 10

y, y,

w

y, y, y,

BKIY

y,

W

BKty

~

~

.100 0-

~

% scale

• loon

~ y,

f----1!y, r---y;-

~

8

8- 30 Electrical system

3I!.6b RegulatOl'I..c:til\er-750modell .-.glnoIopeed.andb'l!teryoverhl!ating. ,.......:ir,ling lrequent lopping up of I"~"'('wherepoaiblej

. Reletrlng tolhetI>rM circuild;ag",mt shO ... n. H t each c,rcuit uP"' tum I... IlIul t"'tionl .'MIefedolted ines ...IIshown to thel'l!ik>"' l........... onlllecornectOl'.checl< the cl'cuit fOl' each 01 the termlnats" turn uU\g the same lead. therMly t.king thr" r...:lInglIOl'eac:hclrcuil. lnthelirstlesl Qrcull.lhebutbshoutdnollightup.lnthe second tHtcitcull.thebulbthol.*:l not tight Up. lnlhethlrdt&stc;'cuit.lhebulbshoukj ,;ght up. II any 01 the t ..11 Pfoveothefwise. lhe r"llulatot/' lI(:liIiee

'-...

5 Th&teatsOUllinedabovellrllnotloolprool WlhetMl._indicatell'llltlhelJ:'lllisgood. end III other components In lhe charll"'!l ci'l:uiIl>lvebeenchecked.-.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 lT1O
'**

n

Chapt.3)as~. Trace\lle.,.;mgtrom lheregulatorlreclilierlrit.-.ddisconoect~~

IheconflllCtor. ordi,.eonflllClth....iring connector from the unll.according to model 1_IU.... tr.tions,..t .OI' bj

~~==~"orllCtewssecuring

, 1,..",11 the new unit end lighten III =~.ConnecI\IIe,.,.;,;"g'11IIe

......

'Inllall lhe'ight·h, nd slde panel I_ Chapl... 7) or IUlll lan k (s. . Chapl... 3) IS

-

ZR550 B2;ond B3 UK models

~""

8- 36 Wiring diagrams

CD

= ..."'= ........-

=

.

Reference Dimensions and weights Tools and Workshop Tips Conversion Factors Motorcycle Chemicals and Lubricants MOT Test Checks.

.. .REF-1 .... REF-2 .REF-2Q .REF-21 . ... REF-22

Storage. Fault Finding Fault Finding Equipment Technical Terms Explained Index

Dimensions and Weights

550 models

750 models

REF- ' .REF-27

.. REF·30 .REF·39

.REF·43 .REF·47

REF- 2

Tools and Workshop Tips

Buying tools

A

poorqua//tytoolbreakinginuse, csusmg 1nJUI'Y or dBmsge to the component being wtried on, BJlNays aim to purchase tools which meet the T'/Jhwantnalionalsafttly standard$.

oHset by the savings made by doing the job yourseH. As experience and COflfldencegrow. additK>nallooscanbeaddedloena~eth
repaJr and ovetIauI of \tie molOfC)'cIe. Many 01 the specialist tools are expeosive and not oHeo used so iI may be preferable to hire them,or lor a group of lriends ormotorcyde ctub to join in thepu'chase. Asarule,itisbettertobuymoreexpensi'le, good qual~y tools. Cheaper tools are likely to

wear oullaster and need to belenewedmore ohen, nuUay;ng the original saving.

1 Setofrla/-b/aded ~

2. SetofPMipshead ~.-.

3 Combinalionopen-«ld andringsparners 4 Sock&1set (JI81nch

orl/2inc:hdrivrJ) 5 8e/oIAJienkeysorbits

--

W~.ing:T.oevoidlheri$kOf8

, •

Atoolkitisaiunda,mootal,equiremOOllo<

ooMcOng and rapamg a motorcyCle. Although thef8Wili bean initial expense in building up enough tools lOf servicing, this will soon be

Thefollowinglistsoitoolsdonolrepresenl the manulacturer's service tools. but serve as a guide to tleIp the o_decide which tools are needed for this level 01 worl<. In addition. items such as an electric drill. hacksaw.liles. soldering irOf! and a workbench equipped with a vice. may be ne&ded. Although not Classed as tools. a seleclion of bolts. screws. ~~ ~a:::~. and pieces 01 tubing always

6 Ser 01 TOfX keys orbits 1 Pfiets,CUttf./f$and

se/f-Iockinggrips

8 Adjus/ablespanners 9 C-Spa«l8fS 10 Treaddeprflgavgeand

For moreinformatiOf! about tools. refer to the Haynes Motorcycle WOIk$hop Praclice Tech8ook(Bk. No. 3470)

Manufacturer's service tools Inevilablycer1ainlasksrequiretheuseofa service tool. Where poss ible an alternative 1001 or method of approach is recommended. but sometimes there is no option if personal injury or damage to Ihe compon&nt is to be avoid&d.Whererequir&d,serviceloolsare rele(f&d tointhertllevanlprocedure. seMce tools can usually only be purchased Irom a molorcycle deale< and are idenl ifled by a part number. Some of the commonly-us&d tools. such as rotor pullers. ara available In aftemlarl<et form from mail-order motorCycle tool and accessory suppliers.

11 Cableoilerdamp

12 Feelergauges 22 COn1inu/fy leSter

13 Spati(pluggap

'""""""''''''

14 Spati(p/ugspameror doopplugsocJ<.ets

15 witubrushand

"""'-

,., 19 F\Imp!)peoilcan 2O GreaS6gu11

23 Barrerycharger 24 Hydrometer/fCrb;!ltety specificgravilychec/f)

25 Anti-fraezeleSler(fcr 1iquid-cooiedengine3)

Tools and Workshop Tips

---

, r....,...-"""

....

:=::~~

REF-'

REF· '

Tools and Workshop Tips ~

~ WOIk is made much easier by raising the

:~u!'c:':i~~m~ r~;=io:~~~ ::eI~~ Mydraulic Or pneumatic types "en in the dealef 's worksl>opare8!1OUodln""slm~ti T

yoounde
•

1I 'ltiaedo!f ground ...... "'. thflbil<emusl be

ramps ;""orpa.ate 3 front wl\"110<;811"9 damp

whic~

eM be adjustoo to SUIt diHereol

~~:;;e~:r:"n:S;~f~;g~~en::, ~~; damage the lyre · use wood blocks OIl eac~ .Jdetoprevenllh>s • Se<;ure the bike to the ,amp uSingti" downs (see illllsiration 1.2). If lha bike has on lyssidesland,an d henceleanaalB daJ1ge
•"IIIIIiIl

-'..t"--'

•

Use ptopfielary erlgine 08g reuers or

~lswNchha""ahiOOflash-poinl . such

asparaffin(kerosene),forcl eani"lloH oll. gr_anddlrt · n_usepetrof(gasoliM)1<:o" cleaning. Wear rubber gkwM when hand~r>g

soI\temMdenoine
=~:!~:;t:a,:gerous -

always

Dust, eye and hand protection

1.3 This auxiliary stanes to l l>e 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<

andp
gl""es $t>ould be athand in t l>o workst>op

• Prote<;;t yOU( hands from contact with SOlvents. fuel and oils by weanng rubber gloves. AAeftlatively apply a barrirlrcream 10 yoorhar>d .belorestartirlgworII.lfhanoling hot components Or fluids. wear suitable ~v::.pg

alloYop

What to do with old fluids

Fluids

• OIdclear'lingso/vent . !uel.cootantar>doils should oottlt'poure f!uid up in old oil ~bellt accordingly. and take ~ toa garage or aspoSaf taciijty. Coolacl yOUt"

cont"""".

~~au=~I~:::-,locationof"t.<:h sites Offing

."tisocilII_

OILCARE •

Aux iliary (paddock) 51ands are wKlely

available from mall order companl .... Of moto,cycle deale,s and aHach eithe< 10 the _ a' '''o<swingarm pivot (see llluslrat ion 1.3) . If the motOfcycle has acooI,ontand,yov canS<JPlXll1ilunderlllecrankcaseto prevenl jt toppling wh~st "'ther wneel is removed tsee iIIust",tlonl.4)

.-;

:::::::,:.<>11 To_tIM ~lioroolJlOO'

Joc.oiIrecycling

=;;-'/!~ In thfl US,4, nole IIt.1 any 011 suppl;'r m"sl~I"sed oil'OIrecycling.

Tools and Workshop Tips

REF- S

• S9~ - locking nuts .. ith .. r hava a nylon irIsert. or two $p'ing metal talls, ora shouldef which is S!"ked into a grOQva In thashaft· 1he~ advantage OVef conventional plain nuts Os a resistanca to loosening due to vibration Thenyloninser1typecanbrlus&daoomberof tirMs.but muslberenewedwhentl>emction oftllenyloninsertisredUC«l.lewhentheoot spins fffleIy on the shaft. The spriog tall type canbereusedunlessthe tabsBI1Idamaged

2 Fasteners screws,boItsandnuts

• Fast ene< head type. are eithef of hexaOOflal, Torx Or spt ined design , with intefnal and exlemal vef$ions 01 each type

~~~must berenewedevery

~=e~~:lr~;ns.;; i~ndc~:':~e~

L,_,_",_;o-w -.."'_!"~-).-~o~~~w~._="""' ),

~:~::n~:o"=~~

molorcydes, The con"9I'Itiona l . loUed or Ph illips head des;gn Isosed l orce
sprill1l washer (C) 9nd SOITated washer (OJ

of a plain oot. Common appIicabons are Wheel

•

1

The split-ring spring washer works by

applying axial tension betwe8fllhe lasl91'1ef head and component, II Itan,,"ed, il is latigued and must be renewed. If a plain Iflat) wash..-isusedonthefast ener,po$ltionthe springwasllerbetWe8fllhelastener8l1dthe plajRwasher • Sarratedstartypewasher-sd iglntolhe fastener and compOll""! faces , pr..v""tlng 1oo"""lng. They ar.. oft .... usedone~tncal 8IW1h (groond) connections to the lrame. • Cone type washers (sometimes called Bell .. villej are conical and when tlghtoned apptyaxiarteos.ion betwe.'l the fastener head and component. They must be ;"'Slal"", with lhedished side against th e component and ott9l'l carry an OUTSIDE marl
~"::":-~::"=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 preve
Nuts and split pins 2.2 Er.lemalTorx \A),splined (B) and her.a{lOr"l Ic) l ast.. ners, with

correapondingSQCkels

• ConventKmaipiainnu1saraosuallysix skied (see Illustralion 2.4j. They a", s;zed by Ihreaddiameter-and pltch_ H;gh t""silenut. carry a number on one end tod""oto their tlllflsde s!rengih.

2.6 Bend split pin (con .... pin) anns a s

• CertajRlast...-son tile motorcycle have a tensilemar\(jng on Ihetr heads . lhe higher

shown to s&eurea plain nul

themarl< i ngthes t r on~'thelast9l'lef. H igh

Cauflon: If Ihe cas l ellated"ut sfots do not allg" with Ihe shafl hoi.. aflar

1ensi\e 1as1eners ll"""'allycanyal0orhigher marking. Never reptacea high tensilelastener with one of a tower t.... S;1e strenglh.

ti¢rtanlrrgloIMtorqu .. seW"g,lightlHl th .. "ulu,l/ilfhe""xt$lotaljgnswlthlhe : - " .. verSlaClre"lhanultoal/gl1I1S

Wash8fs l see illuslration2.3) • Plain washln ar.. US&d betwoon a fastoner headandacomponenttopreventdamagelQ th e componentOf lo spread theloa<:lw~

lorque fsapp/ied. Ptain wa&her8C811al$ObrI

~~em:l~es~~o:'" orO. s~I~~I~I:mc..~~::~ washMsareoltenL>SeCiassealingwasherson 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<1 condition, AlwaY'S install A.pins with t heir closed end facing forwa rdslsee illostration2.7j

REFo6

Tools and Workshop Tips

2.1 CoITectlitting01 R-pln. fUTt:¥wlndicaleslorwiW'ddil'Ktion

Cirelipi i_ illustration 2.8) •

Circlips (som9lllTl8S called lI\aP-nngs) are

used to"'alnCOll1po1le<1lson a shaft or .... housing and have COIrespooding .~t&l'f1.' or in ternal $In 10 penni! removal . Parallel-aided (machined)dr~P5CiVlbeinslalledlllth.. way round in th." groove. whereas .tamped cwcips(WhiChhaveachamferededglonone lace) must be installed with tile "hamlet lacing away from the directlOO of ltvust load (see Illualnllion 2.9).

2..10 Ali9n circ~popening wilhllhaftchannel

Tllread dlam8lerx pitch (mm)

• Circlips can waar due to the thrust 01 compon.nts and become loos. In their grooves. wit h the subseq uent danger 01 becoming dislodged In operalioo. For thl. reason.~alie.av\sed",erytimeacirclip

isdisll.rbed. • W .. ecirclips&laCOflVl1ClOfyusadaspostOtl pin retainN>g clips. II a removal lang I, provided, 1ong-1'IOII8d plifltscan be used to dislodge tham. otkerwisa car.ful usa 01 a smalillat-bladed scrawdrivaris necassary. Wire clfclips sh-ould be renewed 8V8I"y time they are dlsturbad.

• Always UN eirelip plier. to ramove and flsI3IIclrClipt;e.pandoreomp<ess themjusl lIfloogh to remove them. Alter Inslanallon,

rotate lhaeirclip In lIS groove toensure), I. securely SIIBled. If installing a cirelip on a splir,edshaft always align its opening w,th a shall channal to ensure the clrchp end ••re well supported and unlikely to catch ,sa.

Illusltalloo2.IO).

r:l

~:::::"

__ L ~__

2.9 Con-eet Ilnmg 01 a stamped corcllp

• Diamalaroiamaiathread(screw.boIIor stud) IS tha oul$lde diamat ... 01 tha ttv... dad porlion (sea lIluslralion 2.111. MOIl motOfcycle manuiaclUfarl usa the .SO (IntematlOfll\l Standards Organisation) metric system al
b+" ,F :_ Q

~

MS.I .O

14mm 17mm

MIO., .25 Mt2.' .25

• Thelhreadsolmostlast~araolttlt r!ght-handtypa.le lhayaratumadcloclr.wise to tight . . an<./ anti-clockwiseto 1ooseI1. The ra ........ silUaHoo applies to lett-hand thread lastenars, wtlichara tumad Intl-clockwise to

:~r~~e;s a:~eCI::iS~~~r~~~~tl~~t-~~n~ ~7!~~lcon\ltlfltionalright.

Thread diameter and pitch

2.8 btemal .l
M5xO.8 MIl x 1.0

M8xl .25

J

-~~-Fi

Seized faatene,.. • Corrosion 0' .~Iarnat Inl"",", due \0 watar Of reactlOfl between two dissimIlar metals can occurOY8r I pariod 01 lime It will build up SOOf1.8f in wet cOndit>ons Or '" countries whe<. sa lt is used on the road, during the winter. II B lastener is severely corroded it is hkal v that normal methods removal wlU lail and result In its head beIng rui~. When you attempt removal. the last..... thread should ba !Ieard to crack I_ and unscrew eaSIly - II it ~'t, stop there baloradamaglngsomethong. • A smart tap OIl ttlt head 01 tile lastener will ollen SlICceed in braaking IrooCOfTOSIOfI which has occurred In the threads (se. Illustration 2.13) • All aerosol penetrBtlng fl uid (such as WD-4O)appIied tha night beforehand may work lis w:ry down Into the thread and aase removal. Oepardingon the Iocation,you maybaable to maka up a Plasbdnewalaround the last.....

0'

\"

~andfililwtlt1par111nl1ngfUd

II

,

:to . c

11

~

2.11 FIISI_rlenglh(L),thniaddiameler (0). thread pitch (P) and l>ead lize{AF)

~ . ---..,

k.....

....

2..13 A sharp tap on Iha head of a fastener will often break free I corroded thr ead

Tool s and Workshop Tips •

REF. ,

11 yoo 8rD woaing on an eng;"" inlemal

c"""'P"""'t.corroslonwll l nlO$l~k~no lbe a

problem due to the well lubricated enyircmmeot Howe..... components can be V«ylighl aoo an impact drivef is a u...1uI too ",lreeingthem ls ee i~usltabon2.14)

2.1 6 Uainu a .... mmerand chisel to Iree e seized last_

Broken f •• fene,. end damaged h ••d. •

• WherecQ(.OII'onhascx:c urredbetw....n diSSImila r metals (eg SI&el and alu min ium alloy). the application 01 heat 10 the lest..., ...

:-:d:t~:.~t~h:?:~~~~:= .alLure caused by the corrosion . Whether I\eatcaobeaP!)lieddepeodsDI1thelocalion of the fasleoer - any 1SUn'0000ingCDl11por'101nts

Illh" M",,",ol a btokenbc>'IQlSC,ew iS

acc
oflhecrenkcneorbol1s. n(l SC(8",s lrom whic h Ihe head has broken oft (s •• jllustralion2.17), S1ooscana!sooo""""<Wed IiDcI
~~~~I:,.,O~~~~a~~":;aa~~ ~~;r:l~dG~: thlll"'gestsile"xt,acto<poss;ble, ootavoid leaving too s mall II. wall thic kr>essothe,wise the 8~ t, aclo , will me,ely forca Ihe f~.t e ne , ::::!t~oulward' wedg ing it in the casing

:n/c::=!.:~t~X~~~17a~e=' !7e~dl~ ..... $Cr\IW iIIustralion 2-201

~in,~witgripthtfas t enerand

it

~om

thecasong 1_

by

01 the stOO8nd using a.panoe, 0<1 lhe low9r ..... t (... illuSlrat ion2..18). (>lid

;~:I:~U!':a~:,a~.~51"'::~:~:~nbe~':'~~ ,_~_. . . .~_--. u...-.gapa;nt . tripperr.eatgunorckll_iron. or by immerSing th"component;n boiling waler - wear protecti ve glove. to prlll/llni scaldingorbools tothehards

2.20 ... lhenthreadtl>e " xtrac1or antl·clockw;se into II>e fas tener

•

If Btapertypeextraclorisu5
the lasteMr .o that It Is firmly wed9ll(! ,n

~:wU~::: :~,aotO< (anti·cloc~w; ...1

A W" rn",g:Slud " d n clors .... .lll =f:~'!::~:~:':~ I:~!

-ask"n enginto. abou! SPark

~ ~:tC::0;~!i~o~b;:,tfa~:":

amsJonffthI511sppens.

I." illustration 2.161. Thi.

00ad unscrewed will damage the

faste(>/)(,

but

mo
irnportantlye~t,emeca,emust be taken nol to

L,"'--IL._ ,....._ L.:=

dama.gethes",roundiogcornponent C..mon:~fNI_e<>rnponetIt

bH!gHC_if;~oI"""'~1IIue th." the bon, nllt 01" ","'toW . wll ... ,,..

,,,'_11 """,,dollOl_crew/fw/lh

Iortto, In.,ud wOO '". , •• , .... b.c~ and forti! wll ... "';"'to"c. I, felt 10 _ltIttwd~.

• A bo[1 or screw Which has broken olf below 0< IlIVei wllh Ihe casinll mu.t be e~lracled using a screw extractor set. c;.,tr" punch Ihe faslener to central i.e the "~ II bll thlln ",m a ho ~ In the lUI""", Ine iltu.tration2.191. Select. drill bit which is 'pptoximale[y ha~ 10 th'''''-quarter. the

•

A1tarnatlvely. the

bro~ en

botVsc rew can

~e~;~~ =~::..!h~,h~led~::~;i:~ thread lOSer!. It I s - . .tial that the drif6r>g is Clltrilldout squarll!y 8r'Id to the COffect depth olhe(W ise the ca.il>\jmayberuined-ilin

!",,~::t':::,~~cauSQ tIlecorrectsilll~orsocktttOslipwhen

force is 8PPIied. Of the typesofspll!"ll>eff5ockel avai lal>te always use a si'.point type,alher thananeigl>to.- 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
• It ispoos;bletodrillout theoldthl"eadand IlItap thecompootnl lo lhenext thread slle This will work where there Is enough aurroonding maln l and a new boll or screw can be obtained. Sometimes. however. this Is notpossible-lWChaswheretheboltlserew passes through anothe.- component which must also be SUItably modifltld, also in eaMS where a spark piugOl'oldrainpiug cannot be obIaned in a iarger diameter thread sil:e. • The diamond-lI&Ctloo thread Insert (often known by ~$ popular trade name of HeIi-Goil) is a simple and et!eo::lr.. method of renewing lhe thread and r&liWW1g the original size. A kit can beptJrct\ased which contains the lap.InHfl andinstaiinglool (SM illuslration2.25) .DI1I out the damaged tllfead with the size dfill specdied (_illuslrlltion2.26l.Citrefulyretap thetilread (see IlIuSlrallon 2.27J. lnstall the

2..29 . • . and thread into the c:omponern ••

... break off the lang when complete

Insert on tile installing 1001 and Ihread

~ slowly Into place using a Ilghl downward pressure (sae illustration s 2.28 and 2.29). When positioned between a 1/4 and 1121l.mbelow thasuiace~lhIInstailinglOOlandl,OSO!l

thread diameter and pitch required

Ihe break-oft tool to press down on the tang. breakrIg~off (_illustntlon2.3OI . • Thereareepollythreadrepairkitsonlhe market which can rebuild stripped internal threads, although Ihls repair should not be used on higIlload·bearing components

Tools and Workshop Tips Thread locking and sealing compounds • Lockingeompoundsareusedinlocations wherelhelaslerwlspronelOlooserWlgdue 10 vibralloo or on Important safety-rlllate
"'" •

Before applying kicking compound, make

SU'ethalthellYsads(lnlern<Jjende~tem~are

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
External mlcrom. ter

--.

Note: The eon~."tionsl ana/og
•

AlwaY'> check the calibration 01 the

micromtter before use. With the anWs dosed

(0 to 25 nvn type)/lf set over a test gBUO('I (lor

Feeler glluge.

the larger Iypes) the scala s.hould read zero (... llIuatration 3.2) ; make sure that the anWs (and lest piece) are clean Iirst. IvT'jdiscrepancy ean beadjusled by referr'ng to the instructions supplied with \he tool. Remembe< that the micrometer is a precision measuring tooldon·tiorcetheanviisdosed.uselhellltchel(C) ontheenclolthemk:rometer lo elose~. Inlhis WIr'/. a meastJred Iorce is always applied. • Touse.llrslmakeSlnlhattheitembeing measured is clean. Ptace the anvil «he mlcrome«er (I) against the item and use the «hlmbIe (2) to bring Ihespinclle(3jllghtly;"to contact wi«h «he olher side 0 1 the Item {Ie. 1IIl111ralion 3.3). Don'llighten the Ihlm!)le down because this will damage the micrometer -insteact llSII \he ratchel (4) on the end 01 the micrometer. Theratchelmecllani$m apptiesa measured force preve
0'

.. . ""'. ",

• Themlcrometeris .eadbyrefemnglothe ..... tcaltonthesleeveandthellfV'Uar1lC8le on the thimble. Read oft the ........ 'ir$tto obta;" the bllsell"l8aS..-erner'Il , then add the fine ~ement lrom the ItWnbIe to obt ..... l he overall reading. The linear s.cllleon the lIJeeII8'epfeserltsthemeasuringrangeolthe mieromeler(egOt025nvn).TheIMUlarICale

• Fe9le' gaugea (Ot blades.) ara used lOt measuring small gapland clearances (see illuSlralion 3.1) . They can also be used to meBSureendlloat(lide~ay)olacomponent

on a shalt where 1ICC.st;' not possible with a dialgauge • Feelergau.g.ese1sshouidbetreatedwith care and not bent or damaged. They are etched with lheir size on one lace. I(eepltlem clean and very light.." oiJed to prevent c:orrosionbuikkJp.

3.1 Feeler (JiMIQ81 are used 'or measuring smallgaps anclelurances-thieknessi:s marIIedononelaceolgauge

REF' 9

When measuring a clearance. seIeGt a

gauge..tlidlita~alidingfitbet-.lhelwo

I AnvIl 2 Thimble

3.3 Micrometer eomponent partl 3 SpndIe .., Rlltehet

5 Frame

6l.oc:1ringlell8r

REF· ,0

Tools and Workshop Tips

on Ihe thimble wi ll be in gradualions of 0.01

~~~m:.erk;:tm:eI:H =)O:50;~f~

46,000

~~~~e~~n:ca~~, ~~~e !~a:~:a~~:=e :~: thimble's scale. Always position the eye directly above the scale otherwise an iMCCUf8tereadingwiliresuil In Ih ~ example shown the Ilem measures 2.95 mm (see jllus lralion 3.4)-

3.7 Expand thelelescoping gauge inthebore, lcx: k itsposilion . .

Most mlCtOffietars have a locking lflver (6) on It>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<" measurlng clutch ~ale lrictlonma terialandspringfreeleog th$

• To use the conventional linear scale vernier, slacken off the vernleo- clamp SCf"ews (1) and set its jaws 01191" (2). or inside (3). the item to be measured (see illustration 3.11 ) Siide the jaw intoconl act, usi ng the thu mbwheel (4) for line movemen t 01 the Slid ing scale (5) then tighten the clamp sc rews (1) Read oH the main scale (6) where the zero on the sliding scale (5) intersecls it. tak ing the whol e numb er 10 the left 01 the zero: this provides the base measurement . View aklng tile sliding scale and select the dMsion which

3. 10 .. :..~~ :~:r~~::; gauge li nes upexaatly w;th any 01 the d ivisions on the main scale, noting that the divisions usually represents 0.02 ofa mi llimetre . Add this fi ne measuremenl to the base meas","ernent 10 obtain the total reading.

Tools and Workshop Tips

REF- "

Plastlgauge •

Plasrigaugeisaplasiicma lerialwhlchc"n

be comp ressed bel wIH!n two surfaces to measure the oil clearance belwe&I1 them, The

Width of the compressed Plastigauge is

:~:~~;~ l~g~I~:r'an~e calibrated scale 10 •

3.11 Vemiercomponent parts {linear gauge! 1 CJ8mp screws 2 EJ(lemaljaws

3 Inlemal jaws 4 Thumbwhee/

In the eMmple shown the item measures 55.92 mm (see illus/ratlon 3.12)-

5 Sliding sc/J/6 6 Mainscale

I

Base measurement Fine measuremeot

7 Depth gauge

55.00 mm 00.92 mm

Common uses 01 P lasligauge are lor

measurlng the clearance belwOOfl cran kshah journal and main bearing ,nserts, between crankshaft jOll"'al and big-end bearing inserts. and belween camshaft and bearing surfaces. The following oxampledesc ri bes big-end oil clearance measuremomt • HandlethePlasligaugemale
Totall'lIure • Some vemiE!l" calipers are equipped with a dial gauge for line measurement_ Before use. chec~ that the jaws &reclean, then close tIlem lullyandched< lhatlhediaigaugereadszero If necessary adjust the gauge ring accordingly. Slacken the Yemief clamp scr
1 2 3 4

Clamp screw EXfernal jaws intemaljaws Thuml>whee/

5 Milin scale

6 Sliding scale 7 DitJlgauge

3.15 I'Iastigaugeplacedacr05SWttjoumal

REF· "

Tools and Workshop Tips FaiI"-ndWIQE~.Thegaugew'All>old 1h&.-lirIgII:'d~f_.

0/1 pre.sure gauf1e' • An oil prflSln gauge is uHd tor ..-...ing .......... oII~_MosI~ oomewilhaMlolMlaplers,ofilthelhreadof lht'-"e-oIIPOOOI I _"""'tno Iion3.~1). "thIt

'ake·oll pol"lll)«:iMod by tile motorcy<:1e maroulactur ... Is an I xtem.1 ",I pipe union. m8~'

,urI that tile spec;lfIed replacement

orOon"UMdlo~oOlslaJVa tioo

.

AdiIII~with_ableadapterscanbe

•

Oil preeaure Is measured whh the ""9'"

IPf(:llic .pm) moo olt8<1 the

<>sed 10 determine piston position BTDC 00

,unn;"" la'

IWO-Slrok.~lortheP'Jfl)08eS ofign~ion liming.The~,acI/Ii'II_andouitablelllngth

cold and tIOIenginI.

~.,.In.I"ledlnltleplac.olllleS!Wk

plug

and tile gauge zeroed., TOe. II IIle

I

manufaclurerwillllf)tlCilypres.surelimilslora

Straight-edge and surface plate If checlUllg lIMo gaaket face of.

pistonpoeilion .t:pIICiIieOal.1• ...., BTOC,

•

roIatllhlenginl_102.00mmBTOC.U-

eomponenIlor~pIace.sleeI"""o<

IIowIyto.w.dllO 1.1. mmBTOC.

precisionstraigN~-=rossltegaskett_

_

..........

8n)'9IIP~theStlaJght·

Cylinder compre ..ion gauges

tdgen~wr(hfeelergauges!_

.

A~pugeisl,lMdk><

=..::

measumg cytirIder cornptNSioo1.

the rvbber·cooelyPeorth.,hreadedadapl..

=~.:

E~,*

. . .tr1Itio<13.22).DleckcMgonallyacroullMo

COtI"IfIOIW!IItICI_mountIOg""'- l_ illuatrallon3.231.

!:!:~~::f::: r--~------''---"

head. AO 10 3OOptI!O 1020 s.j Iypegauge (lor pet'OVga.oh .... eoginn) will be suitable l ormol~.

!n.The~~~~~=

typel or the g''''III'!ldapt_lCrewad into Ille ~1lMd~l)'IMl t _ilk.tstnotion

Ir ...........

3..2OI.CyIincIIr~is!M8SUredwith '-=;~~~~~~~

lheenginltunq_,bulnoIn.....ng·ceny OUIthe~lest .. describedln

Tools and Workshop Tips .

en.ckongind~c;Ompc>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 • ...,.oIdlOd
gIesIand,....~.

I\ano;Ie Ihould bt dry - oiled tll,.a Ira necesseryincenaincin;u:Tl.tanc.. lttld thl .......... lloCIlW ....... ta .. tl!ilintc acoour'Itinthe specl l~ d 'orque Ilgura. Slmil.... 'y, tile manulKI ...... ...-ylllolptoCitylhe~ oImr.d·Ioddng~ .

.

~ nleatati"" .lnll'llsway,noIllllthltlll r_of

tl>ejOint f1,heldbyone laslene, endth. componentS .... not likltl\ltoo;lOstort . e llalighleningSlqVlll"'ce i,provided,work In lhe REVERSE of 1M, but ~ noI, _ Irom the outskle n. ina cr>SSoClOS$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'IQtmullipliedbjtl<:lueqooll IQl'tl<.'&.

• TI>4o 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

..,~.ApplylhelO
c'*'k the HIring. Where dill....... ' IIwHd ~ ..

tul ...... HoC\nlhecomponent. .. • rIH tight... the large< diameI. anN • Wilen The torque wrench lias I)ftn Ilnl,h60 wllh, "lena the lOCk (..h... lIPI)IIcat>ltlatldrully~o/I i \s~ t ing t oz .. o

mi.

eew,elylov-the<wittloulmov..,..."tin t he

·donot ...wolhetorq .... ...........u.tenslor>ed. Alto. do nol lIM • 1000q.........,..;h lOf

joInI.T"'ac'u.IIOtqUeM1ling~on

lIIockerWIga-.-.

the IhfNd 1lIZ1. boll or nul fIIaI"'IWId IhI! ~oItl-.COfT"II)Of'OIIllSbeIn9t.1c1.

•

TooMtle torquem.yClUMlhelall..-to IOOHn d ... 10 vibt.lIon . _ .., 100 mucI> IOt~'" will dlslort !h. jolnl !.e" 01 tho> companenl or cauu I~ 1..I _ t o s/Iea< oft .oJw')"I.ticktothllspecit;.,;ttorql,lltHI1ir!g

U./ng _ torque wrench e ChKk lhe c.libr.tlon ot 1M torque Wf.,-d\....smab_~hM .... ~r.-.oe 1oru..Iob, Torqwwretaehel . . ~" H!n(N.-wton-mMreS!.kQlm(l! II {pounDS.IMt). IIlI In (inch·

pourdII.Oo l'IQC conf\IMlb4f1w1t11lb1i1 • .t.djUlltne tool to tM", ... tdtorQVton ltyQUrtorqoe

Angle·tlghtenlng e ~I ...lu .... ofl..,~.Iig"'," d8gr1teStottir>al 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
~~~"IUCI1 ,,""cyWndef

lhelC. (_ ~l usl .. tion4.11.

e

A sequenc. "ulually provldM by m. manulacM", eitller In a diagram /)0' 8Cluall~

~hksllOlca~ed"' t~""itlspecified.

car.tullyconvMl 111. ,111"" ,... Conv...-.iOI'I

man.fJdinlheulling. l1nol.lll wayssIM '" II>e_aod lfl'Ol'l
FacIOtll!.A lNlfllllact......-_I"""g;v...e torqUeHttng as IlWI\IIIlBto TO Nm),e__ Ih.nalingltligl.q· "'_caMHI 11»1001

SKwing" boIl .... nut. IInQo!<·I""~t. then set

rno;tway_I~_HllingL""_

IhI t~.......::flandJjgh I .... eacI!tast_ by ....... ........., .. ~untilthltlinal torque iI reached. 8y lolowrng Ihispo-acti<:e.

torque lNIy be ... prMMCi .. 8 Nm " I Hm. Sornotlorq... _enchltlhaVIt ......,hodof IoddngIheSItttinIJ ... 1tIaI~ ... ·,~entIy ellertdtUWlO lISIt•

--

...... b-,"'"'"""" 1he"'911 ""t""

4.5 When t1ghlening,wonfrom tIM! InslcMoutwards

REF' 14

Tools and Workshop Tips

the joint will be held evenly and w ill not be d,stoned. Important joints, such as Ihe cylinder head and big-ernl laslene,soflen havetwo-Qr thre
Applying leverage • Use tools al the COfrect angle. Position a socket wrench or spanner on the boWnutSO Ihatyou puH il towarOsyou when loosening. II this Can'l bedorJe. push the spanner without cvrling your finge-rs around It (see illustra tion 4.6)-the spanner may slip o r the tastene' loosen suddenly, resulting m your tingers beingcrushedagainstacomponem

• The same equipmenl can be used to install bearings. Ma ke sure the bearing housing issupporte(l 011 wQOd blocks and line up the bearing irt its housifl\l. Fit thebearifl\l as noted on remova l - generally they are installed with their marked side laCIng oUlwards. Tap the bearing squBrelytnto its housing using a driv8f orsockel wh;ch bears only on Ihe bearing's outer race-cootactwilh Ihe beaTing ball s/rollers or inner race will destroyit(seel llustratioos5,1 and5,2j. • Check that the bearing inner race ane! bal lslrollersrolalet'eely.

noaccesslolhe~anddrawlhegearpintOf1

Off the shafl IIswe\1 (see illustratioo 5.4)

5,4 Where 00 access is available 10 the rear of the bearing, it is sometimes possible to draw ofl the sdjacent componenl

4.6 11 you can't pUll on the spooner to loosen a fastener, push wilh your hand open

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
pl.Inersandslide-hammers • Wh .... e a bearing is pressed on ashafl a puller will be required to e xtract it (see illustration S_3). Make sure Ihatlhe pulle.clamp Of legs tit securely behind the bearing and are unlikely 10 slip out II pulling a bearing 5.5 When installing a bearing on a shaft usea pie<:e 01 tubing which bflars only on the bearing's inner rece

~~~~~~~~~~v:C~:~~1 ~~eS:~:1 ~~a~:~~; conta<;tstM out{tl" f3Ce ot the bearing, not the ballsiroliersO(innefraee. AIwayssuppol1 !he casing around the bearing housing with wood blocks , otherwise Ihere is a 'isk 01 f'acture. The bearing is driven out with a lew blows on tlte driver or socket t,om a heavy m~lIel Unless ar::cess is s.... erely ,8Str;cteo (as w,th

=me~;~n~~t~Sait i~i;:;~~;:ra:,~d ~~ bearingtokeeprtsquarein,tshoustng

5.3 This bearing puller clamps behind ttwl be&ring and pressure is apptledto the shaft end to draw the bearing ofl

• Where a bearing locales in a blind hOle in a casing,itcannol bedtiven OJ'puttedout as e!escribed above. A slide-hammer w,th kntfeedged bearirtg pulle< attachment w,1I be required. The puller ettachment passes through Ihe bearing and when tightened expandstolil lirmlybeh indtl\ebeaJlnglsee IlIuslrallon 5,6) . By operaling the stide· hammer part 01 the 1001 thet>earing iSlaJl'ed out of rts housing (SM Hlustralion 5.7) • IliSpossible,illhebearingisolreasonabte wotghl,lorillodropoutolils housing illhe casingisheatedasdescriDedopposite.lllhis

Tools and Workshop Tips

REF- ' S

Tempereturtlchenge

, BoItOllengfhollhreadedbar

2 Nuts 3

W".sI>erjex remaldlamele.-grealet"than

• 111h
thebeafonghousing.

rubinglf1,emaldOamelet! ..

Tubog{it1 temalr.1iamfl lersuffit;ient'Q accommodate bearing) ~ Susp6fISiOIlatmWllhbe¥ing 6 Tubing(exremaldiamelersliglll/yIlmilIJer rllanbearlng) 7 Washer (exlamal diameter slightly smaller

A •

Wamlng: All of ' h.,. methods requ/,.. c:a,.. In us. to pr.~.nt 5(!ald/ng .nd bums to th.

h,nd,. W•• ,prot"'tlvaglo~es whanhandllngho' ~'s.

//uln/:>earlngi

bearIng puller

mel hOO is attempted. fo Ist prepare a wOIk surface which will enable the casing 10 be lapped facedowf1 10 I>eIp (lislQdge l ne bearing

- a wood surlace is Ideal siroce 11 will nol damage the casing's gaskel surface. Wearing pmle<:livegloves, lap Iheheal&d casing sev8fal l imes aga,nst the work surlace 10 disIodgolhebea'ing under~sown weight (see ~Iustralion 5.81.

5.10 Drawing ItIebearing out 01 the

5.12 A~singcanbainvne rHd lnasink 01 boiling water 10 aid baar!ng remOV31

..spensionann •

TO'KlllICIthebearinglbush)'OUwiII~

a long boIIwrlhnut (or piece of Ihreaded bar

5..a Tapping a

~$ing 1_ dQwn on wood blockscan oftendlsiodgoeabeartng

• Baarings can be lnSMlled In blindholas ~~~e' he driver 00" sochl melhod deacrlbed

Drawbotta • Whe<e8bea'iOIjOO"bushissetio lheotyeoi a componenl, 5Uch as ~ suspenSion Irnkage arm 00" conr.ecHng rod small-end. removal by doilt maydamagle lhe~t.Furlhennore

a rubber bustMng In a $hOCk absorber eye cannolsuccessl lAybe~ou i olpolit",,",. 11 accessisavaiiableloa~presa,lhoe

taskisst,aigt1lforward. llnot.adrawbllllcanbe labricated 10 exlracl the bearing or bush.

wIftltwonuts),e piece of tubing whichhas8tl Intemaldiameter larger lhanthe bearinglbu$h, anoIherpoeee of 1ut:.1g which has an eKlemal diameter slighlly smaller than the t>eanr.gJ bush, and a selection of washers (see mUlllallons 5.9 and 5.10). NOle that lhe pieen 04 tubing musl be 01 tile same 1eo91h, orlongef, lhoo lhet>earWlg/bush • The same lot (withotJ\ the pieces a ltubing) can beusoo to draw lhe new bea/;l'\9Ibush bac;k ....toplace (see illuslration 5. 11)

5.13Uain9 a kx:aJi sedhaat , ourc. 10 aid bearl"9 removal • II heat ing the whole casrng no le tha i plas tic: components. SUC h as th o neutrsl switch. may suiter - remove them beforehand

• Alta, healing. remove the bearing es deacrlbed above. You may tha t the expanSion is sullic:lenl lor the bearing to lall out 01 the casing under its own welgh l 00" with alight tap on the df
"nd

• tfll8C8SSClfY.theCllSingcanbelleate
REF· '6

Tools and Workshop Tips

• Installation of bearings can be eased by plac ing them in a lreeler the night belo' a installation. The steel bearing will contract slightly.a!lowing easy insertion in ~shousing

~:~~ i~~:e~cu:se~;r:hf~~!st a l ling $t~ring

Bearing types and markings • Plajns~lbeorjogs.balibearings.r.eedle foller bearings and tapered roller beari"llS will all be lound on motorcycles (see illustrations

5.16 Typical bearing marking

5.14 and 5.151· The baU and roller types are usually caged betwe-en an inner and oule. r&Ce.bull!flCilged~ariationsmaybetound.

5.18 EJlample 01 batlJoumal bearing with damaged billi s and cages

Bearing fault finding • It a bealing oule r race has spun in its housing . the housing material wil l be damaged, You can use a bearing locking compo<J<1d looond the outer race in placeil damage is not 100 seve,e. • Shell bear ings will tail due to damage 01 I he ir work ing surlace. as a result 01 lac~ 01 IubricaTion,cOI1'osion or abrasive particles in the oil (see illustration 5.171. Small particles oldir! in the o il may embed in the bea ri ng material whereas larger particles will score the bearing and shal1 journal. Ifa number 01 short journeys are made . insullicient heal will be gooerated to drivfl off coodensation which has blJill up on the bearings

race when

$pUn

racewithlheolherhand ( see ~lustralion5. 19j.

The bear ing should be almOSI silent when spun; il it gr8tes or r8ttles it

rs worn.

• Shell bearings (ollen called ;nsen!) are usually found althe crankshaft main and connecting rod big"end whete thecy are good at coping wrth high loads. They are made of a

• Oil sea ls shoold be renewed every time a component is dIsmantled . This is because the S
phosphor·bronze

cran~casesjoined .

malerial

and

are

impregnated with sell-lubricating properties . • Ball bearings and need l
ba lls o r roilers between the races, They reQlIireconstantlllbricationbyoilorgrease and are good at copingwilh axial loads, Tape< rolle ( ~ari ng scons i slotrol l ersselina

taperedcag9setontheinnerrace;lheoole< race is separate. They are good al copong with axial loads and p<event movement along the shaU - a Iypical applicat"m is In The sleering

'-' •

Bearingmanulactli rersprodllCet>earings

to ISQ si.e standards and slamp 000 lace 01 the bearing to indicate rtslnternal arJd eXlernal diameTer. load capacity and type (see illustration 5.16).

:ron~:t~ai~~:t~~~~rs~~~~~t :.:ous:!o:~ suspensionmoonllng eyes. Fibre blJshes have alsobeenused;nsuspensionpivots.

• Ballandrolierbearingswililai l duetolack 01 lubricalion or damage to the balls or rollers. Tapere(l-rollerbearings can t>e damaged by overload ing them. Un less the bea ri ng is sealed on both sides. wash il in paralfin (kerosenej to remove all old grease ti1en ai low it to dry, Make a visual inspeclion looking 10 dented balls or rol lers, damaged cages and worn or pilled races (see illustration S.f8) . • A ball bearing can 00 checked lor_by listening to ij wilen spun. AW'I a film ol lighl oil 10 thebeariog and hold ~dosetotheear- hold the outer race with one hand and spin lheiooe<

• 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
loinslall itlnlhecasing-tappOngontheinoer edge will damage lhe sealing lip

Oil seal types and markings • Oil s!taIS8rEtu$Uallyoflhesin.gle-lipped type . Double-lipped seals are found whefe a liquid or gas is 00 bOth sidas of the \<)int • Oil seats can hard801 and lose their sealing abi'ityif Ihe motorcy<;le has been in slorage fora klng period-renewal i$ the only soIuHon • Oil seal manufacturers also conform 10 the ISO markings lor seal size - thesa are moukled inlo the outer face of the seal !see illuslration6.2j

impregnaledin I/s surfaca before applying addilional$OOl;mt. • When chooSing a sealant make sure it is suitable lor the application. part icularly if being appliW in a, high·temperature area (l(in the vicin ity 01 fuel. Cerl ain manufacturers prOOUCflsealants in e
Breaking a sealed joint • [email protected] theuseothBrd setting seatantcan cause two <:omponents to stick together so tighlly that they aredifficuft to separate using fingtlr pressure alone. Do not resorttousingleversunlessthereisap.-ypoint provided I(l(this purpase (see illustral lon 7.1) or else the gaskel slXfaces win be damaged • Use II soft · laced hammer (see iIIus trntion 7.2) or a wood block arid corwlI<1lional hammer to strl~e the component near the matingsurtace. Avoid hammering against cast extremities since Ihey may break o!f. Iflhis method fails, try usirog a wood wedge between the two components

Types of gasket and sealant • Gaskets are used to sea l the mat ing surfaces between components and keep Iubricants,lluids,vacuumorpresswecontained within the assembly. Alumiruum gasl<ets are

sometlmeslouod allhecylinder joinls, but mosl gaskets a"., paper-based. 1111'Ie rnal"' g surtacesolthecomponentsbeingjoinedare undamagedthegas ket can~inslal leddry ,

although a dab 01 sea lant or g rease will be useful to ho!d il in place during assembly • RTV (Room Tempe rat ure Vu lcanising) silicone rubber sealants Cure when exposed to moislu re in the atmosphere. These sealants are good al Iilling pits ()I" irregular gasket laces. bot will tend 10 be lorced out 01 the joint under Yefy high I(l(qve. Ttley can be used to replace a paper gasket . but lirSI make sure thaI the widt h 01 the papef gasket is not essenlial to the shimming 01 internal comOOm.mts. RTV sealants should not be used on components containing petrol (gasolinej • Non·hardening ,semi-hardll<1ingandhard setling liquid 9
Removal of old gasket and sealant • Paper gaskets will most likely come away complete. lealling only a tew traces stud< on

REF' "

Most (;(Imponen ts have one or two hollow loca l ing c/Owe/s between Ih e two gllskel I_s. "" dowel cannol be removed, do no l ,""sorr 10 gripping il withp/iers- Itwlll aimoslcerlainlybe distorl&d. ln stallliclose-fittin g$OC.e l or Phillips screwdriver Into the dowe' and Ih." grip I/Ie ou l . r edge o f Ih. dowe1to frN/t. the sealing faces of th
• Verycarefully!!Crapealitraceso'ga~et away mak ing sure thai the sealing surfaces are not gouged or SCQred by the scraper (see ill us\rat ions7.3,7.4and7.5) .Stubborn deposits can be removed by spraying with an ae r o~9ask etremoller.Finalpreparationof

REF· ,8

Tools and Workshop Tips

7.7 Akitche
stiff"""

can be mBde wllh '''''Y liM abraslvepap",ar a plastic ki tch"" "co.. ,,,, the \lUke!

\.... illustrations 7.6 and 7.11 . • Oidsealanlcan beocrn.p9d<>rpeeledoff COI'I'IPOII"" t5.dependingonthely~onginaily

u,ed . Notethatgaskelremo"" lcompoundS ar.

available

.

to

avoid

scrap
the

components c~an; make , .. ,elhe guket remove<.utslhetypeolsealantusad

<;haion, O>stal a....wO-nngovereacl>p;nolthe link and inaer1 1he ~nk tI\'OUOh the two chain endSI_iIIuslrllt ionS.4). Ir\SIal aoewO-ring ove, tile """ of each pin. followed by thoe

""""

sidep
Breaklnll and Joining final drl.,. chaine

~(H'I~;!,~h~~~


~~as=t~~~Sa(~n.::=. !!ta:

a~lo:x'~a~:a~ ~~~~I:~ ~ :~:,w~=~:;~";k=

: c(H'In
sltCu ,.tyriveted togalhMusing a na lN sott rivet· lype link. Nev", U5e a clip-type conn<>etinglin k ln.teadol a,ivel -typellnl<. except in 8n em",g-&nCy . V8r1ous c""in l>g tO<.>lsareavatlable. elther as separato too" '" C<Ml1t)ined as illustrated in tile accompanying photOQ(aph s _ read the

iMtruc:tionssupptiedwith lhotoolcareTuny.

& 10 result

()V$(

~e~:£::~~z7=;

:,/:"e::::,,::: ::Z-

likely

ol tha ""It link pi"" (s"" ill usl ration 8.1) Ope
• N
thecrtain(.",, ;lluslralion8.2j. OnanO-ring chain. remove the O-ring. (see lIIuslralion

s;de-pjatecverth
S.3).Carryoutthe.ameproc~eon the

othefsofllinkpn

;;,=;,:::,:c::.;,:'=-=c=-=-c= Cautio": C..uhI IJOff Imk ¢". /lMrtlculer1y 011 the

lerger ch. In_, mey

NqU""t"*" e llds10 be fI/ed or gt1I
:=--f"-Ycenbe/l'MMdout...mg

. Checkthal~

have lhocarecl s;ze n

~t~ (~;::~~e :I~; ~~Ik7:

I:"(.ee ;::

marking on the chaIn skleplales illustrationS.to)

• Aotale the chail'l ancI i0oi< lor II>e 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 un5ea1eds , l hen install th.. . Odeplal .. w~h the chain manufacturer's marl
• Position the chain ends SO that they are angag.ed """'H.... 'eaf spt"OCket. On an O· nng

ple t !!$ of t het~dampthelinkandp ressthe Olhetwiso . usetW
Tools and Workshop Tips

the.ivel ends and IWO pie<:es 01 the wood boHwee" a G-c lamp. Operate the clamp to presslhesjdeplateove.- thep,os • Assemble the jO ining tool oyer One p in (fol lowmg the maker's ;rlSlruc tions) and tighten the tooj down to spread the pin end securely (see illustrations 8.8 and 8 .9) . Do

Ihesameon theolherpin

Clamping to pre".nt flow • Sman-borellexiblehosescan beclamped to prevenl lIu,d How wh itst a componen t is worked o n. Whichever method is used. ensure that the hose material is not permanently d istor1edOfdamagedby theclamp If) A /x8k1f /I<)Slj cllmIfJ avBi/abJe from 9Uto accessory shops (see mus/ralion 9./)_ b) A wingrltJl type hosa c!amp {Sftfl illustration9.2}

Final drive chain ./zlng • Chaonsaresizedus,nga threed;g,t number. followed bya sufhx 10 der>ote thecha,n type (see illus tration B.IO) , Cha in type ,s e,the.standlYd orhea'/)' dlJTy(lhic~ers.>OOplales). 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<;uallyaid the escape 01 tluid tram thejolnlIt is preferab le to soften the hose ends ,n hot water and wet the ;"side surface of the hose with waler Of a fluod which will evaporate.

REF· 20

Conversion Factors

Length (distance) Inches (in)

Feet(lt)

x 25.4 x O.30S

.. Mililmet res (rrm) .. Me1res(m) .. Kilometres(km)

Miles

x

0.03~ ~

Inches

en)

x 3.281 '" Foot(ft) x 0.621 " Miles

Volume (capacity) Cubicinche.. (cu in; in') Imper.ruplnts(lmppt) Imperi~quartsOmpqt)

ImperialquartsOmpql) us quarts {US qt) Imperiaigalfonsompga/) ImperlaigalioosOmpgal)

US gal lons (US gal)

x 16.387= Cubic centime(res (cc; em')

x 0.061 '" Cubic iflches(cu in; in')

x 0.568 .. L~res 0) x 1.137 . utresOl

x 1.76

K 1.201

~

X 0.946 x 4.546 x 1.201 x 3.785

.. UtresO) " Utres(Q "USgailons{USgal)

us quarts (US qt)

" UtresOl

.. ImperialpintsQmpptj

x 0.88 .. Imperial quarts Qmp QI) x 0.833 .. Imperial quar1s Omp qtj x 1.057 _ US quarts (US qtj x 0.22 .. Imperialgalioos(lmpgal) x 0.833

'" Imperial galklns (Imp gaO

x 0.264 _ US gallons (US gal)

Mass (weight) Ouoces(ozJ Pounds(lb)

x 28 .55 .. Grams(g) x 0.454 " Kilograms(kg)

x 0.035 " Ounces(oz) x 2.205 " Pounds(lb)

x 0.278 " Nawtons(N}

x 3.6 '" Ounces-force(ozf;ozj x 0.225 '" Pounds-force Qbf; Ib)

Force Ounces-lorce(ozf;Olj Pounds·jo'ce~bf: Ib) Newtoos(N)

x 4.448 ~ Nawtons(N) x 0.1 "Kilograms· lorce(kgf;kg)

x 9.81

'" Newtons(N)

Pressure Pounds·lorce pe< square inch

x 0.070 .. Kilograms-forcepersquare

fpsi;lbflin';llYin') Pounds-Iorcepersquareinch iPsi: lblflrl';iblin'l

x 0.068 .. Atmospheres(atm)

x 14.223= Pounds-force per square inch

centirnelre (kgflcm'; kglcm')

Pounds-force per square Inch

(psi;lbflin'; lblin'l Pooods-iorcepersquareinch tps;;lbllln';lblin')

x 6.895 ..

KiIopascals(kPa)

x 0.01

Millibar(mbat)

x 100 • Pascals(Pa) x 0.0145 .. Pounds· forcepe r sqlJ
(psi;lbllin' ; b'"1fl') Pounds-force per squaralnc:h (psi;lbllln'; lblin,)

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 (mb
.. Millibar (mbar)

x 1.866 = Millimetres of mercury (mm/-lg) x 27.66 .. Inches of w ater (inHp)

(psl; lbflin'; lblin')

Torque (moment of force) Pounds-force inches \Iblin; Ib in) POl.mds-forceinche$ ~bl in: Ibin) Pounds-Iorceinches \Iblin; Ib in) Pounds-force leeIQbl!!; lblt) Pounds-lorce feet \lbflt; lb/t) Newton metres (Nm)

x 1.152 " Kilograms-forcecGrltimetre

x 0.868 '" Pounds-torceindles

(kgfcm; kgcm)

x 0.113 .. Nawlonmetre!l(Nm)

x 8.85

x 0.083 .. Pounds -forcefeet(IIlf !!;lbfl)

Qbf In; Ibin) .. Pounds-for-ceinches (lbfin; lbin) ..

POlInd$-for-ceinc~

(lbf ;";lbln)

x 0.138

~

~

7.233 = Pounds-force feet (Ibf!! ; Ibll)

Kilograms-forcemetres (kgfm; kgm) x 1.356 .. Newtonmetres(Nm) x 0.102 .. Kilograms-force metres (kgfm;kg m)

x 0.738 " Pounds -force teet (Ibl It; Ibll)

x 745 .7 ~ Watts(W)

x 0.0013" Horsepower(h;»

x 9.804 "

Newton metres (Nm)

Power Horsepowe.-(hp)

Velocity (speed) Milesperhour(mileslhr,mph)

x 1.609 = Kiiometres per hour (kmlhr, kph) x 0 .821 ~ Milesperhour (milesJhr.mph)

Fuel consumption* Miles per gallon (mpg)

x 0.354 ., Kilometres per litre (kmII)

x 2.825 " Miles per gallor1 (mpg)

Temperature Degrees Celsius (Degrees Centigrade; ' q = rF - 32) x 0.56

Degrees Fahrent>ejl '" ('C x 1.8) + 32

'It;s common practicll to convert from

mj/g~

per gallon (mpg) to /jtre$/IOO kjlometres (lIIOOkm). wheie mpg x 1I100 11m ,,282

Motorcycle Chemicals and Lubricants A number of chemicals and lubricants are available for use in motorcycle maint enance and repair. They include a wide variety of products ranging from cleaning solvents and degreasers to lubricants and protective sprays for rubber, plastic and vinyl.

•

Contact point/spark plug cleaner is

a solvent used to clean oily film and dirt

from points, grime from electrical connectors and oil deposits from spark plugs. It Is 011 free and leaves no residue. It can also be used to remove gum and varnish from carburettor jets and other orifices.

• Carburettor cleaner is similar to contact polnVspark plug cleaner but It usually has a stronger solvent and may leave a slight oily reside. It is not recommended for cleaning electrical components or connections.

• Brake system cleaner is used to remove grease or brake fluid from brake system components (where clean surfaces are absolutely necessary and petroleum-based solvents cannot be used); it also leaves no residue. • Silicone-based lubricants are used to protect rubber parts such as hoses and grommets, and are used as lubricants for hinges and locks. • Muttl-purpo,. grease is an all purpose lubricant used wherever grease is more practical than a liquid lubricant such as oil. Some multi-purpose grease Is coloured white and specially fOf'lTlutaled to be more resistant to water than ordinary grease.

• Gear 011 (sometimes called gear lube) is a specially designed oil used in transmissions and final drive units, as well as other areas where high friction, high temperature lubrication is required. It is available in a number of viscosities (weights) for various applications. • Motor oil, of course, is the lubricant specially formulated for use in the engine. It normally contains a wide

variety of additives to prevent corrosion and reduce foaming and wear. Motor oil comes in various weights (viscosity ratings) of from 5 to 80 . The recommended weight of the oil depends on the seasonal temperature and the demands on the engine. Ught oil is used In cold climates and under light load conditions; heavy oil Is used In hot c limates and where high loads are encountered. Multi-viscosity oils are designed to have characteristics of both light and heavy oils and are available in a number of weights from 5W-20 to 20WSO. • Petrol additives perform several functions, depending on their chemical makeup. They usually contain solvents that help dissolve gum and varnish that build up on carburettor and inlet parts. They also serve to break down carbon deposits that form on the inside surfaces of the combustion chambers. Some additives contain upper cylinder lubricants for valves and piston rings. • Brake and clutch ftuid is a specially formulated hydraulic flu id that can withstand the heat and pressure encountered in brakel clutch systems. eare must be taken that this fluid does not come in contact with painted surfaces or plastics. An opened container should always be resealed to prevent contamination by water or dirt. • Chain lubricants are formulated especially for use on motorcycle final drive chains. A good chain lube should adhere welt and have good penetrating qualities to be effective as a lubricant inside the chain and on the side plates, pins and rollers. Most chain lubes are either the foaming type or quick drying type and are usually mar\l;eted as sprays. Take care to use a lubricant marked as being suitable fo r O-ring chains. • Oegreasers are heavy duty solvents used to remove grease and grime that may accumulate on engine and frame components. They can be sprayed or

REF.21

brushed on and, depending on the type, are rinsed with either water or solvent. • Solvents are used alone or in combination with degreasers to clean parts and assemblies during repair and overhauL The home mechanic should use ooly solvents that are non-flammable and that do not produce irritating fumes. • Gasket sealing compounds may be used in conjunction wit h gaskets, to improve their sealing capabilities, or alone, to seal metal-to-metal joints. Many gasket sealers can withstand extreme heat, some are impervious to petrol and lubricants, while others are capable of filling and sealing large cavities. Depending on the intended use, gasket sealers either dry hard or stay relatively soft and pliable. They are usually applied by hand, with a brush, or are sprayed on the gasket sealing surfaces. • Ttl read locking compound is an adhesive locking compound that prevents threaded fasteners from loosening because of vibration . It is available in a variety of types for different applications. • Moisture dispersants are usually sprays that can be used to dry out electrical components such as the fuse block and wiring connectors . Some types can also be used as treatment for rubber and as a lubricant tor hinges, cables and locks. • Wa xes and polishes are used to help protect painted and plated surfaces from the weather. Different types of paint may require the use of different types of wax polish. Some polishes utilise a chemical or abrasive cleaner to help remove the top layer of ox idised (dull) paint on older vehicles. tn recent years, many non-wax polishes (that contain a wide variety of chemicals such as polymers and silicones) have been introduced. These non-wax polishes are usually easier to apply and last longer than conventional waxes and polishes.

REF- 22

MOT Test Checks

About the MOT Test InlheUK,all vehiclesmorettlanthreeyears old are subject to an annual test to ensu re t hat they meet minimum sa fety requ irements. A cooent test certificate must be issued before a machine can be used on pub/ic roads, and i$ requirl:Kl t>eforea road lund licence can be is.sued. Riding without a current test C8I'IHicatewill also invalidate yoor ins...ance

For most Owne
owners not being sure what needs to be ctlecked prior to submitting the motorcycle fO(lesting . Tlle sJmplfl answer is that a fully foodworthy motorcyc le will have no difficulty

In paasingtlle test. This Is a guide logetling your motorcycle IhroughlheMOTtest.Obviouslyilwilinolbe possible 10 examine ttl&motorcycle to the

-,---_...

same s!andard as the professional MOT

Electrical System

.... Wilh the

ign~ion

on, check the operation

o l lhefol~ngelectrlcalcomponeot s. ~te:

The electrical compOnents OIl certain sma/'Cllp(Idly mM;hines are po wered by the genBl'8lor,requirlngthatlhflengine/s11lf)1or thischec~.

a) Headlighl and laillight. Check thafboth i/lum;nala in the low INId high beam switch positions. b) Positionligllts. C/leek that lhe front position (orsJdeh"gIlt}lNIdraillight Hlum;nateln this swifchposition.

c) Tum3ignals. CllecJlthatailfiashatlhe comICtfllle,lNIdlhatlhewamingllght(s)

tester, particularly in view of l he equi pmen\ requlrad for some of the checks. However, wor1
Certain exception s apply to machines undar 50 ce, machines without a light ing S)'3tem, and ClassIc blkes- ilin doubt about any of the requirements Haled below seek confirmalion from an MOT laSler p rior to submitllngthemotorcyelelorthetest Check that the frame number is clearly

vis;bIe

_-

prove useful.

.....

'" The MOT lester wlil per10rm a headlight beam height check using speciali sed beam setting equi pment (.H IIluelra\Jon 1). Th is equipment will not be available 10 the home mechanic, but II you suspect that the head light Is Incorrectly set or may have been malsdillsledlnthepast,Y"ucanperform~

rough lest aslollows. .... Posi\lontheblke lnastralghtlinefaclnga brick wall. The bike must be oH Its sland. upflght and wilh a ridersesled. Measure the height from the ground to Ihe cenlre of the headllghtal"ld mBrl< a homontal line on the wall at this height. Position the motorcycle 3.8 metres from the wall and draw a vertical

line up the wall central to the centreline 01 Ihe motorcyc le. Swjtch 10 d ipped beam and check thaI the beam pattern falls slightly lower than the hoI"izontal Une and to the lett of the vertical line lsee illllstration 2).

funclionC0fT9CIIy.Chec~tha l therum

signalswitt;hwot/rscomIClly. d) H8:latd warning system (wheflI filled). CllecJllhataJ//oUTlumsignalsflashlnlhls sWltchposilion. e)Btakestopllght.CIlecJlIi1allhelighl comes on when the front and rear bnliles IIIU Independently lPPIied. Models first IJS#KJonaraflerlstAprilI986musthave abra~eligl1l switch on each braka. f) Hom. ChecI
'"

Check thaI thefei s a red reftectoron the rear 01 the maChina . eith er mounted separalely or as part 01 the tai l light lens. Cheek the cond ition of the headlight, tai l light and tum signal lenses.

2

",.

Home workshop beam alignment che-ck

MOT Test Checks

REF-23

Exhaust System and Final Drive

'" Check that tile exhaust mountings ar" """""• ...-.dtMtlhesyslemdoMootfouiany oIthfl",ar!\lJ!lpensloncompon""ts.

'" Startthamol0rcycle.Whllnthfl,evs a,a Increas«l. check Ihat Ihe exhauSI Is ne;lher rIOIedn«leaking "om enyol~,)ointS. On a linked

~em,

tI NOli Ihal th .. ,, ~hau . t decibel laval rlood""",,·of II>eexh""aljOil assesSlldalthll dlscrflllonol!heteslet. ll lhemotorcydewas Ilrs t used on oral!8<' h i JanlJery 19851he slleoc«mustearrylheBSAU I 93ltamp,Of I matlting r.
......... ., o..chainOfbell drlvemachlnes,cIleck

~':sl~:tC~:~:~!~~~v!':!:~~~~";h:~~ ~~ t:~: ~h='~t~:U::a~~ guard ill In place. ';

check thaI 1M collector box is

On 'hallo:t1v9bikes.cIlecI< l oroil~ing

Iromtl\e~un~_joulingthereartyr •.

r"IOl 1eakil'lgdue lo CO!'JOSlon

Steering and Suspension Iod< check w;lh lheweight of the machiooon ""'Iowerbeetlng (Me WIustr8tion 31 .., Grasplhe lor!< alld8fs OowerleOS) and at!&mpl to push arld pull On thllforks (SM

.... Wlth\l>elrontwheelraiMdolltneground,

~~~~~ c:.1:~cgh:~U~';"~o:~~~I~: l,*tank orbecloseeno.,gh tOlraptheooer"s han<.l. Prollklmscan becau5ed by damaged iocI< stops on ttJe lower yoke and frame. or by tne littingolooo-standa.rdhaodklbal1l

'" Whenpel1ormlnglhekx:ktokx:kcheck. a lso '"'SUra that the stee,;"g mooes freely wiIt"ooutdragornotcNrless.&eering""""""'"

mus lraUon4) .At>.y~aY "' t heSleMnghead

bearings will befell. Note Illal in exlreme C8S
~':kthallh8 handlebal1lare5ecllrely "'

Check that\l>ehandiebargripN~ar e

..

secure. Theysl>ould by booOedto\l>ebar lelt e<>d 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). Che<:k that the suspension components do not foul on any of the cycle parts and check that the shock abso.ber(s) provideadequatedarnp;ng .... VisuallyillSP8Cttheshockabsorbe'{s} and

y'

y' Inspec t the area above and a.ound the Ironl fork oil seals (see illustration 6). There shou ld be no sign of oi l on Ihttforl<. tube (stanchion) nor leaking down the slider (lower

Worn suspension linkage pivots (arrows) are usually the cause of pleyin the reersuspension

checkthatthereisnosignoloil leakagelrom Its damper. This is somewhal restricled on eenaln single shock models due \0 the location of the shock absorber .,. With the rear wheel raised 0 11 the ground, grasp the wheel at the highest point arid attempt to ptJlI ~ up (SH illustration 8) . Any play in theswi09!lrm pivol or suspef1sion linkage bearings wil l be felt as movemen t Note: Do not confu~ play with actual suspension movemtlnt. Failure to lubricate suspe nsion linkage bearings can lead to bearing failure (see illuslration9). .,. W~h the rsat wheel raised oH the g.oourld. grasp the swingarm ends and attempl10 move the swinga.m f.om sidtt to sidtt and forwa.dsand backw
Grasp the I wlngann at the ends to check l or play In Its pivot

bearings

MOT Test Checks

Brakes, Wheels and Tyres

...... ....

W~h

::tt!o;~~o:,0 :=the~~~ ~:= is underpr8SSlX&, and ched
lhe wll"'" ",'sed ott the ground.

appIythebrak"thenffH~oft,andcheckthat

thewtleet Isaooul to ' evolve freely without brakedfag. 1/ On disc bfakH . exam ir>e the disc itsal' . ;~:c,thatiliS8ecll,elymOlJntedandnot

1/ On disc bnlkes, vOew the pad material thg leve-randcableorroo>snottoo oreat (see illustration t2j. Check alsOlhal the operating Oeverdoesn't fou l any othe,

components 1/ On disc brakes.

e ~ami n e

the

ne~ible

~~r-~~

~~k~;:t::.: ~!k~,!; ~io.:!i damage. Where a bd the:1 its lasteners ar".ecur&d by se4Hocklng nuts orcast..la\1Id nlltswith spirt pO-osorR·pins(seeillus\ration l3). '" On moo:Ie4s with ASS, check that the self =~.warnjng l ;ghl i ntMinslrumentpan" l

V

The MOT tesl«wil perlorma test of Ihe

mQ t orcycl" ' $btaklnget!ic~ncybasedOtla

calcu lalion 01 ride, and molorcycieweillht. AAhough lhiscamot be catT>e
you can at lust ensu'" thai \he btaking sy,tems a,. p
__

~~

REF' 25

_

~/~ feel(bleedolair l frt .spoogy) and

pad material. For drum brakes. check adjustment, cable or rod operallon and &hoe lirlingthicknesa

.... .,...

I/ Checkll>ewheeicondition.Casl_. s/IOO4d~"""t'omc'acl<sandHoI tl\eb'J'" IIpdeslun.a ll lutane, sshookl~sec ure

Spoked wh .....

sIlould be checked l or

brokM .cormoseor~nts pokes .

1/ W~hlhewheeiraised"') (SH Illu stration 14). Any play feU r.e.e indicates wt>eeI 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 prope
seIf-locl
0<

<:a$teiateo:! nut w~h a !lI>n·

pinorA·pincanblll!sed ( _~ "' stration171

... WhHI alignment i.

chec~ed

with the

motorcY'Ole olf t "",standaooariderseated

Withthe lrontwt;e.ej poin\in"st ,ai ght lll1" ad. lwQperf9ctlyst ra;ghtlenglhsolmelalorwood

andplacedegeinstlhesklewalsolbothtyr"'l (see Illustration 16). lhIIltaIleacl>$kIeoftho> front tyre musl be equidistam 00 bOth sides . ... C~Ck t~e l yre tread depth, tread cond ition and .idewall cond ition (s ... Illustration 151

typesmust becompatibleBndbewltal:Oefo< road use. Tyres marked NOT FOR ROAD

Incorreclwh .... lalignm...,tmay b.duetoa cocI<ed.- wheel (ott..., as the ,esu/I of poor

or ~ m lla'.

chain adjustmMl) or rn a>
tI' C/leck thaI the rider and p
"" Ch&ckforcOt'osiooon lh" ' rameorany

swivel joinl, . plus specilk: wh.!II alignment (t""·inlrequi,em""t •. AddlllonaIIY, tyr,, and

motorcycle u.... 0wnMs are _ to cl>eck 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

<-- -

;

Preparing for storage

,-~\".

~,.

l'

.;

• ...

_ _ _ Iho _ _ or .... 1lk'lP4otTOWS1_

--~.- .,.,-.-.-

j1.

........ f'r" ~

c.:.nn.a._"' ....

/ I

•

~_~

l....."..-j-~ .... - -

,

,~'

__

.

~I U. . . ...lbblebatterycnarg... - Ihlskit also as""ss batte ry condition

Illen awitchoflandallowlocool_ Tapeapie<:9 ol tnickplastk:ov .. tn.sl l ~ rend(.) ( .e. illu stration 5]. NOla that some advocate pouring a tablespoon 01 motor 0;1 into the $ilencer(s) befO<\I$IlaIi1lg IlIemolf

• Che<:k t he e'eclrolytelaveland top up i/ ~::,ss~ryt=%\I"""'1 refillable balter;"s)

•

Siora the bauery off themolorcycfe and

away I,om any SOIJfces of fire , Po. iliOf' a woodenblockundeflhflban"'Y~~;"losil on

ttleground • Givelhebau&ryatrk:klecharoe loraf9W hourlI~WYlTJOr1 th(fl,Hlllustratlon7) .

Tyres • Plata tha m. e on Itscenlreslar>d o,,,n au~jliary .Iand which wil l support the mo\ofcycla In an uprignt position. POliitioo wood blocks UIlderthe Iyf... to keep them ofI the ground and to provide insulation from damp. If the bike is being pulintO long-I""" . 10raga,;daa lly bo!hlyras should be off Ihe ground; 001 only wi~ this prot8CI thtItyreS, bu1 will also ensure tMI 00 load is plac8donthtl steering head or ...heeI bearir>ga • Deftateeachlyreby5tol0psl,nomoreor

the

be~ds

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

~ u b~&Quent

Battery

"'~

• Rem<>v
• Lubricate all

Pivots and controls l e~er,

pedal, stand and

Getting back on the road Engine and transmission •

Cha~ge

lhe oil and replace the oil lille.-. II

~i~ ;:~~=if~::I~~, ~~k :~:t:~

=;ion...

nic~

ocCurs

through

• Remove the s»arkplugs. Using a spoultypa oil can,SQUOrt a lew dropS 01 oil;"lo lhe cy1indor(s). This will provide initial lubric:ation aslt!e pistonringsandborescomesbac kinlo contoct. SMVice lhe spark plugs. orfil new OMs.arxl .... lagthemin lhe !lngi""

• Check thaI Ihe clutch I",,'t s tuck "". The plates can s tick togatn... ~ lell stang Ihe bike beck

..

~~~:::~~ t~~~::;er t;: :-":.~~~ opfIfaled clulche!l, hoIdthedlllch lever back ag , lnslthe hAnd letlarwlthastrongelastic band or-cable He tor a couple 01 hOu." (see illustrationS) • If the air inlakes o,sllance.-end(s) wer.

~k~eO~~;~:~":s~t~~~Sl

tOOtreSI p<.ot points, If orea.e nipples are fitted 10 t~ e rear ""spensio~ component.

~~~=:~~t'~~::~ Cycle components • AWYe ... axprottoetanttoalipaintedand plastic componenlS. Wipe otl any e>es. do

:: r~~H!::!::~~ :~~~..!~e seals • AWYavinylCleanerlolhe !lllat.

Storage conditions • Aim to Slore the t:>ike in a shed or lI"'age which does not leak alld is r.-""tromdamp • Drapa an old blankel 0' bedspread over the bike 10 protect il lromduSI anddi,oet conloct with sun light (which wil lade painl) Tlli s al . o hides Ill e bike lrom pryingey6' Seware ot l!ght·littingplasticcovwswhich =::W~Oon tO ImT1 _~leon

pr" • .,tativa, 011 or a , tablli_tdded to the 1ueI,'hlnandllulh~lWllndditpoMot

Il>eIulolMOalbly. lIl'IO lCtionw.lakenwitJI 1helueltankprb 'ollorage.~ited"""'lhaI ll>eoklluellad~ot

__

~wi l lJOoII

;;:'~o!tkne. ReflIIl>eIuel!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'NOll
" Iha motorcyct. has bHn In long-term

IIDf"08,...-lhe brakelluid..-.ddulchlluid ~aQPIicabIe) . Oependingon-'lhebiltehe5~ "or«I.Ihe~.cablesendllosel.....,.haWl

r-.niIlbIedbyrodoents. Makeavisual_

Frame and running gear • 0iI .. pIyotpoirM8IId..-. e Checlr.1Iw lyre They_ definitely need InIlaling II pres .....eII_e rlducedforll
-.

1'<"""".

. lubrto;at.lhel'iruold""."h.aIn~ . Remove...,ptOIectiII.COIItlng~1O

1he1ontll.CM(stanchionlJlinoItIW.....,._ destroy tMlork _ _ . " the fork tubea w.,.en'tprouctKlandhllvtoplckltdU9fU11 spot., •....ova them wi'" v.1')' lin. ,bralYe pajW a n d . - whh .... _ POhh. • Cheek that boIh tni<.. OP'f'lUI COI'NoCt~. AWfeachbr.... lIIto:landclwicktnatM'.not

REF' 29

due to a aeized oper&ting cam, cabItIOffod

_In~ledi$ll..ot>edwlrlngloomlape.

~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
eonllrm banery condition wilh. specilic gravilycheck. • OnMll«l(MF)banarles.lI l~batr.-yhu

sIKlingcallpertypes.du. to~ lonoltl>e

noI....::«YIdfln/

sllderpina. If the b"ka doe1n'\ I'M aft.r '.peale
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!)ItI
<:>ow.,

manuaI . No,.: It",.f>jg"bMn "' J~

1or'/Ongllme.ok/lullorecarCutellor .btbcl:aQetnl)'be'.... probIfIm~deposils h ~I!Ot3C1<>b/ocJI/et3-lIlcarbuterta"

c.\N"",

doesn',

prove

SIlCalSS/ul

I....

c&
• Oocelhlotnglnillal ."ned. chlck lhat till light • • lum afgnall If'Id 110m work properly •

T'Ntlhebll<egentty tOflhefl,.l r1caand

=~k':, :eI!:I:".:~elhe

REF' 30

Fault Finding

rna Sectiorl provides all easy •..terence-guide to the fI'1O<" commoo fault. t~Bt a,,, li kely 10 afflict y""r machine. ObviouSly, the

01 possible causes , starting with Ihe simplest or m05t obvious and ~1I5Sing1n$ l ages\o lh.mosIc...,pIex .

opporttHlllies"''' almo.tlimllle ssfOff8ult. IOoccll'''5a r.... u~ol

Takll nothino lor g ran1 9d. bul above ali apply libera'

'1uan~l ies

of

obswfefailur".aodlotr')'andCOVfl(a1I~tualil ies wouk:lrequir9"

booIc lndeed ,al'lU!!lber havebeenwritl!lfloothe SUbjecl SuccessfuIIrOl.l~esOOot ingiSnotamyst eriCllJ5 ·blackart'butth e

application of a bit of knQwledge combined wllh e systemat ic and Ioglc"l approadl to the prGblem. Approach any Iroublesllooling by ,.... t accurat&tyldentityingtheoymptomaodthenc:heckingtlYougr,th<> l;st

1 EngItN doNn't ata1 or Is dlltfcun to darl

o o o o0

NoIUtI_ __ .....

o

NoSl*l
StarWmotor.x-...~~

S&irtermotofrotalWlbutenglnedoesnollumover ~WClbbutenglnewon'II.m~(seized)

O ~

..

O S-att...SI8fIlng

0_'" 0 __ 2I'00I' rIIfIIIInII .., low ."eed a

FueII_ mixtlnin<:<:>
O Com~1ow D Poor~

3PoorrtllJlllnOorno,.,..,..,trItIh.".."

o o

FlfIroglncotreCt FueUllirmbcturllncorr.c1 O ~1ow KnocIdrogorploklng

-.CIutch_ o

D ~~

0 __

o a

Engine o-..es

Fuel/air mixture incomd

O ~lOOhigh O EngnIOad~ O l~ign~. O

_~

'-D C~I"'pping

O c...tchnat~compIot8Iy

a

OoMn'~IntoIlM",or ..... dC*tI~""lJITI O J~OUIoigeer o ~

T~m&in symptom ofl lauH is ~ inl~t.. <1 as a rna;c.- t>eadOng t>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. FU<1her Information shoold besougnl In tl>e 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<.e

""' ......

Brownsmoke

12 Poor hMtdIllffl or .tablllt)I

o o o o

HllndlebarMrtitotum HandIebaIshakesorvibrMes eX<:fltl5lvel)' I-lAndleberpul8 tOoneskie Poorshocl8OrbIngquallties

'3Btw1d,.,,~

o o o

Brakes .... SpOngy.don 'tl'lold Brakele_OI'ped8jpulsm., Brak8Sdr8!l

14E1edrlc1t1 problema o

BalterydMdOl'weak

O Balt"'Y~

Fault Finding

REF' 3'

Engine doesn't start or is difficult to start Starter motor doe.,,'t rotate

o o o o

Engineklll switchOFF. Fu~ biown. ChecI< """ (Chapter 8). Ba1teryvollagelo .... CheckaodrecharQabatle
o o

pvshed_Hthet91. yclicl<s,thenthef.... ~ls

ln lhewiring o<mO\Of.

Starterrelayf.uIty.Cheek~usinglheprocedureIroChapter8.

Starter switch noc contacting , TheCOOlactacoUdDewoit, corrod~Dfdirty.Oisas""",bI . andcieanlheswitch(ChaPl.8).

o

o

WimgopenOfshO<1oo.Ch9ckaDwilingCOlY>8C1ionsand ha
o o

contacts. Clean 01 '9j)Iacethe swilch as necessary (Chapter 8)

o

ChapterS. Faulrystarter eifl;". ,oIayordiode.Chackthe ;..nction box IICCOfding to \he procedJre in Chapter 8 .

Englnekiiswitcho:lelectMl.ChllCkfotWIII.dirtyOlCOlToded

Fauityrl8Ulr. IOtslde standswitch.Check lhewiringloeach swilchandth.switc hitse~accor d O\g lotheproc~es in

:~r

o D

DamaoedkUel'educt;oog.earOlstar\8f oears· ln""""land'~

Ihedamagedpar\S(Chapter2)

o

No spa,* or weak spark

o o

o o o o o

wo'*_ but engine won't tum over (seized'

Seizedengnecausedbyoneormorflint8fr"lallydalT\aged componeol$. Failu .. due 1o w.... ,. abu ... or lack of .... bficalion Da'nage.,.,inclcodeselzedvalves.follow8fs.camshatls.pI!tons.

b!>erinQS. Ae1 ... to Chapl8f 2fofenginedi ... ssembly

o

o

o D

No fuel in tank. Maln tuelcock fi~ ... cIogQed.Rernovethefuelcod
either a ""Y bad batch offuet wilh an unusual additive has "-> uud.OI somfIOIIlerfofeignmat8flalhasenteredthetar"lk. Many times a118f a macl"llne has been SlOfed for many monlhs wfII>ouI "'lVling . thefvef tums to a _amish-like 'k:!uid and forms depos~S

cleaning does not heip. replacethe switches (Chapt8f 8) D Wwing shOl\edorbfOkeobetwelln: -,/gnItiotl(mairl) switchMd engine/lilswirch (orbiownfuse) b)rgnirionccnrrolUll~MdMginekils"';fch

c}/gnitionCQlllrnlunltMdignitioll HT coi/s d)IQnifionHTcoi/sandsparlrplup$

a)/gnltionconltolunltandpulse 9l"1Ml10l coil o Make surethatellwiringconn«:tions a .. cl6an.dryandlight LooI
Comprenlon low

o o o

o

o

o

o

FIoaIheight incorrect. Cl>eck and adj'-'Slasnecessary {CI>a;lte<31 Float ~Ie ... ive womor stuck open. A piece oldirl. rust 01 other deb!is can caus.e the valve to seat improperty. causing exC8$!l fuet to be a
o

~"arxlsealare wo
o

ohoukI l;)e,epl&cadwithnew onas/Chapter3) Starting t~ue in<;OI,o.et. Under normal circumstancasQ .•.• ~ alf thecarburettorlunction. vesoundjlhemachinesllouldstar1 with little 01 no thro(lle. When li>eeng;ne is cold. thechoi<e s hould be operated Irld the engine s taried without opening the th"otlle.

Cytinderheadnot .uf1icifw1\tytig~teneddown.lfthecylinOer llead

or head is damaged H the problem has persistad 101 arry length of time. The IIMd boIt.should be lightenad to the proper torq .... In the sequence (Chapter 2).

cor,"'"

ImprOP!lfvalvecleat.....,..ThOS lMlln$ lhel ihevaive isnotclo$ing compIet~andcompressionpressut .ls leak ing paslthevalve

ontl",inletneedieva lves and)et s. Thecalburett~shouldbe

Engine flooded

Spatk plugslooM. Aernovelhe pUgs81ld 1nspec1fhejrth,eacls Reinst.alland tighlento the specified IOIq .... (Chapt .. 1) Ossuspect..::!ofbeing loose.then lhera·s ar:hanc, ltIafthegaskM

,8fTIO'Iedanctovemauledil<.YainOngtheftoatchambersdoeso·t SQfve theproblem (Chaple<3)

o

:!niI';:~: c,,"(s) delectRoe. Check the coils. referring to Chapt8f 4

IgnflionOlkiRswftchshorl"::!. ThIs IS usualtycaused bywater.

:=,:,::~==~he=:.c:.~H

Q"ankshafl.eoonec!ingrodbearings.OItran~sionoearsOl

No fuel flow

Igni!ion s witCh OFF. Engine I'Oftagelow.Ched
D ~:atOl ooildefecti"". Check thecoll.relerringtoChapt"4

o o

motor rotate. but 8""lrte doe. not tum

SlartllldJtchdelactive. Inspacta->d ,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

imprope<1ytiglltened I'ead bofts. Machine IhOp resurfacing or

o o

head replacemem ill necessary (C~ter 2~ Varv. spring broken or weak. Caused by component lalllQ or wear, the springs musc beo ,eOPIaCed (Chapter 21

Eogineidl.speedinoorttd.r...... idleadjustiogsoIWl.Oltiithe eoglne Idles at me speeified rpm (Chapter 1).

Valveoot_t jngproperty.Th isl' Cllusedbyaben1~(1rom cwer-rewingorim~vatvead~l , bumedva.tv..",seaI

(.,.,propeor carburabon) or IrI acwmulation 01 carbon deposItS on tho...,.t(frOmcarbutation""lubricalion~).Tr-.vatv .. ITJJS! be; cleaned andIor replaced and ll>eseats-w:ed II possibl.(Chap t er2~

Stallseffer1rt3rtl"fl

o o o o

Intake .... leak.OIecktor looseCllrt:uel!or·t<>-inlakernnni!ok:l connectklos,loo:oeormissingvacuumgaogeadapterC8P5
o

Imprope'chokeaction,Makllso.nthechol<,linkageshallls getMg a tuil i troke and staying in tt.. 0U't poeiUon (Chap!.. 3~ Ignilionmalll.nc1lon(Chapter 4j C8rbure"or malfunction (Chapter 3~ Fuel conta minated. The fuel can be comamJnat«l with either d in Of water, or can chl
Rough ldl.

o o o o o

Il7ition mallunction {Chapter 4) Idle speed inc:omIct(CI!apter 1)

c.tuellDlSllOt sync:hronlsed.AdjlJ$t ~orswith"""""" Gauge or manorneterwt (Chap1el' 1). C8lburel!or maWunctlool (ChapW3j. Fuelcontaminated ,Thefuel canbeoontamln8ledwitheitherdio1

~::::=~!:.""~t;:~::i:::"W:::sit (Olapter 3~ IrrtakeairIMk.CIIec:Iurel;!or_t
o

2 Poor running at low speeds o

o

o o o o o o o

Battery YOItage low. Check and recharge batlery (Chapl .. 8). Sparkplugsfouled,delectivoeorwomovt(Cllaptert) Spar1
o o

Pulse """erau,rcoll defeclive (Chapter.) IgnitlonHTcoil(s)def$Clive(Chapl ... . ~

Fuelllllr mixture IfJCOITfICt

o

pojlotscreomOUIofadjustmer>1(Chapter3)

o

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

o

IWbIeEod hoIescloQge
o o o o

o

C~ttors{Chapler3).

passages(Chapt.... 3) A7r f.lterclogged, poourettor intal«l rnanWoIds loose. Checl< kw' crack5 . ...-s. tewsorlooHclamps.RoopIacelhenJbberinlal
o o

~Slon rings worn. weak, t>roI<en. or . tlckJlIIJ· Brokenorstlcklrlg piston rings uwelly indicate . lubrication orcarburation prot>lern th;tlcau_ ..xcess carbondeposieoOl$tliz ...... lOlormontile pistons aod rln lJ$, Top-endovemaulisoecessary(Chapt ... 2j Piston ri"ll·to-gro.,.... d-ance excessive. This is caused by e.llCe$Sl\lewear of the p;stonrI"IIlaods. Plstonreplacerner1t is _sary(Chapter2j Cylinder head gasl<et darnayed. tflM head I. allowed to become loose. ortfe>ercausesexiremetyhiyhcornpressOorl.tIIe hNdgasl<etmey!eak.Retorqulrlgthllhlladlsootalways sufliclentt".eslOrelheseal.sogasl<elrep!acemeotisroecessery (Chapler2j C)II1nderhlladwarpecL Thisiscao.mdbyoverfleatJlgor improperty tOghtenedheadbolt•. Machine $hopresurlao:;;"II or h.ad replacement is necessary (Chapler 2~ Va lves¢ns;Jbrokenorweak.C&used bycornponeollailureor _ ; the spmO'l must be replaced (Chapter 2j. Va~notseatiogproperly.This ls causedbyabenlvalve(from

ov ... ·.ewing 01 mproper valve adjustment), Ilumed valve OISM! ~mpropercarburation)oranao::um . . tionofcart>ondepositson theSM!~romca1burationorlubricatiooprolliernal.Thev"'"

must becleanedandforrepiacedanclllleseal$servlcedH possi!>Ie(Cllapler2).

spl~orperishEd(Chapter3).

Compression low O

o D

o

Sparl
oompoiele/yandcompr ... sioopressureisl .... kingpoastthevatYe. Checl< ancI adjust the valve de«ances (Chapler 1)

C)'tlIlderandlorplstOl1 wom.ExcessiYewearwii cause IXImpres$iOll ptessUre loleak past tile rings. lhis is usulily ~bywornrings ... well. Atop-end""erhaul is

_oary(Chapter2j

Poor acceleration

o o o o

Carbu!«t~leakin\lordlrty. OverhauItilecarburet'lOt1o(Chapter3~

TllTliognoi advarocing.Faultvpu'"lI""'"",torC<Jilorignitofuntt (Chapte r.) Ca rburetlors not . ynChronised. Adjuslthern with a VIleWlll II"uge set or """""",ter(Chapte. 1). Eng;neoilYisco5ltytoon"1l,UslngaheaYieroiliha1tt\at recomrnendedinChapt .. lcandarna\Jetheoilp<Jmpor lubrlcatior\systemaodcauseoi-aoontlle~

o

BrakMdtagging. U$ua\lycaused byclebri, whiCh hat entered IhII brlllcepl$tonseals.orlromawarpeddlscorberltule.Repei'as .....:essary (Chapt .. 6).

Fault Finding

AEF· 33

3 Poor running or no power at high speed Firlnglncorrect

o

o o o

o

Piston ring-te>ilfOCIW 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<:essary (ctlaple<2) Cylinderl>Mdwe
A1rfilt&r_lrIcted.Cleanorrepl_ft~&r(CMpt&rI).

Spa.1< I*'9"fouled. defective or worn DU! (Chapter 1). Sp8tkpb;JcaporHTwlringdefec~ve~ tersland4).

Ioase , or~ ex~carbonbuild-uPon t ha pis~DI1crr:N
D ~~~. capsootmakingconta.ct.Make suretheyareproperly

o o o o

Incor..ct epark plugs. Wrong type. heat rar>ge or cap conlig0f8.tion.Checkandins18.l00lTedplugs(~t ...

l).

19nItioncontrolunitdefective(Chapler~).

Puise generator coli defect1.te(Chapter 4).

o o

o

o o

1mP"(l!)&rIyllg1tteoedh6adboJ1S.Machineshe>p~or

19nitionHTOCIO~,j delec:tive (Chap1er4).

FutJllair mbrtll'" inctuTeCt Alrbleedhoiesclogged.RlMt"IOveClVblre!lorandbiowoutalJ passages (Chapler 3). Alrlilterclogged. poorty sealed or missing (Chapler 1). Ai r fi~... housingpoortysealed. Look!orcracks.hoIesorlooH clampsandrepaceor,.rdefec:tiveparts(Chapter3). FueI ...... ellOO higll orl00 low. Cheek the fIoal heighl(ChapI.. 3) Cart;o.nnorIntal<emanifDlds looH.Check forcracks,breaI<:o,

o o

hlllidrepiacemant la necessay(Chapter2). Vatve.poingbrOkflr"lorweBk.CausedbyCOl"llpC>flerttlai..... or w...... thesprlngs mUSl be replacad (Chapl.. 2). Vatvenotseatingproperly. Thisis causedbyabentv1Jlve~rorn

over-rewlngorimpropervalveadjustment).bumedv...... orseat ~carb
IhItseat(tromca.w.mc.norlubric:a1ic>npr<>blems).ThevalYe!l mustbeclaanad;n:llor replac:edand th eseat1lserviced~

posai~ e (ctlapl ...

2)

le;noriooseclamps.Replac e l herubberlnlakemanffoid joi nt . ~

o o o

o

split orperi5h..:l {Chapter 3). Jet needle iflCOlTectty positioned or worn Cheek and adjust or repIaoe (Chapter 3) Malnjlllctooged . Dirt. water or O1hercontamlnanls can dog the mainjom;. Clean l helue1tapr.~er. th. in·I ..... 1iler. th.1Ioa1 <:Nrnberarea. and lhejels and C8
Knocking or pinging

o

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>
o

eompfWss/on low

o o

SparIosa.f:iemovethe plSj)eC(ed of being loose. then there·s a chance that the gsske1 or head is damaged ~t he problem has peraisted lor arry length 01 Ilme.Theheadbolt.s/"o:Iuldbelightenedtothepropertor~ in

o

1tle correct sequenoeo (ctlapter 2). Impropervaiveclearance. Th la meansthatthevalveisnotc~1ng

completely and compreSSion pre!lsure is leaking pasl thtI varve.

o o

Check and adjust the valve clearances {Chapter 1) Cyiirderandlorpislonwom . Excessiv, w""rwiHcause .;:ompressionpressure te>laai<pa$lthemgs.Thisisus..a1y ac<:ornpaniedbywom rings as well. A te>p-end """"'aul is necesaary{Chapter2). PiSlDl101ngsworn,weak.broIten.or s ticking.Br
\hat causes UCe5S carbon dep:>eOls or seizures to form CIfI the pistons and mgs Top-endcwerl>aulisnecessary(Chapte<2)

ca-bonbuild-W ln combuslionchamber.Usee>la1ueladdi1ive 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, lhecyllnde
o

-.

Excess;veffiction in movinoenginepamduetoinadeq ....l e lubric:at>on. 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 thll<>ne recommendedinCllap""'CIJ1damageltleoilpur"r1!lor Illbricat>on sysIem as well as C4IIM
Lubrication Inadequate

AkfiherhousingpOOrlyeealed.LooklO!'aacks.hOI..,orlOO$e eta~ondfeplace ""epajf(Chapt.. 3). height (Cl'IllpIer 3).

F .... _100 low. Check

D

o

Carburettor ntake "*,1IokIs loose. Check lot cracks. breaks. l--.orIooseCllmps . Replace lhol rubber into,kemanilo1djohts spin or perished (Chapt'" 3)

Engfne~lleveItoohlgh_ Theac!d ilionoftoorT"/,JChDiwi!lCII\JH ~risationoflt1.crank c8$llandlneffocientMgirleopon.tlon.

$pari< plugs fouled, MfOCllveorwomQUl(Ct\apt., 1) 10000,ect &par\< plugs (Chapter 1)

o o

Qulchslipping.CanbecaUMdbydamaged,looseorworncutcll oomponems.Overhaul elutch(Chapter2).

Poor~ityenglneoilOfincorrectvisco"1Yortype.OiIls rated

not only accadIr>g to v\aC.h8llS!S)I!Itam. Moslafterrnarkataxhaust systemsc.use the ~r>e to run Ieanar. which mak.1ham run hotter. When !nslaiUng an ItCCHS<>I)' a""au!lt system. always re~

""'carb..-lIIttcn

5 Clutch problems Clutch slipping D D

o o D

o

Cable lraeplay insul!icien1. CMck andadjust cable (Chapter I ). Friction pjat"" worn or warped. Overhaul ilia cluldl """""'bIy (ChepIer2). P1a1n plales warpad (Chapter 2). ~lch springs broken Of weak. Old Of '-t--damaged (from sl lppouklba.aplacec:lw;ltll'lMonH (Cllapter 2). Clulchrelellsemec:hal"lismdelectMl.Replaceanydefectiveparts (Cl\alIIer2j CllJtchcentraorl>c>lJ$lr>g~wom. Thiscauseslmproper

engaoement of th. plates. Replace the damaged Of (CI"IaIlter2).

D

o

o o

INhlcflintumw;ll causethemachlneto"'Hp. OvertIiwl lllacMd1

Clutch sprtr>g tanslon """"en. lJsuaIly caused by a saogad or broken spMg. Chackalld replaoe the sprirql as a set (Chapter 2) Engine 01 deterloratad. Old. th;n. worn out oil will oot jlrO'
o

worn parts

catM lfeapiay • ...cessiv •. CMck and adjust cable (Chapter I ~ Cl!ilch plates warped Of damagad . Th .. will causa clutch drag. ~(Chapter2)

o

o o

Pl'tUng a drag on 1M engine. Change to \heCOfrect weight oil (Chapter" ' ). Clutch hClusingHizedon mainshatl. Lar:k ollubrication._ wrwordamagecancau .... 1heguide !o ...izeon1heshafi. Overhaul of1hecIUlch, andperhapstransmiss>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

(ChapCe<2j.

Gear(s)stuckOl'lIhall. MosIofteocausedbyalackollobrialtion orexcenive_intransmissW:lnbearhg$andDushing • .

Jum". out of gear

Gee. seIecIor drum binding. c.u-I by lubricldion laI ...... or

o o

eJg(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~tofshiftdrumreS<.tts.R.pIItCe

C~chl\Oldiseogaging.s..above.

SeI..:torlorl«$} bentor Miz..t. Ofteo causod by dropping the

D

SeIectorfork(s)""<)frI.Overnauilhetrarosmissloo(Chaptfl'2j. Gear groove(l) worn. o-tlaul the lr.-.smiMion (Chapt ... 2) Geardogsordogslot'WOfnordamaged.n..~shoo1d~

Inspected and fflplated. No attempt eN:>ukI be made to ~ th .... om patts (Chapter2).

o o

s.Iector/stopper8rmsprlng~akorbrokeo(Chapter2).

a-t:hari(Iesllaft"urnspringposlbrckenordiSlorted(ChapClIr2j

7 Abnormal engine noise Knocking or pinging

o o

o

Carbonbuild-uplncombuslloncl\anlbe<. Useofafoellldd/llve that wilidOssoive the a::It-;"'e booding the carbon par1icllls to the piston crown and chamber I!I the _lest way!O """"""'!tie buiIdup.OIh1o:w1.... thacyff\derheadwiMh .... tobe'~and deCart>onized(C!\apIer2) InoorrectorPOOl'QUai >tyIuft.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*l
overhea~ng.

Ineon-ectva/VeCIearanc",Ad.lost th. clearancea(Chapterl) Vaiveaprlngbiokenorweak.Checkandrepiaceweakva"" oprings(Ctlapter2). Carnshaft orcyt;nderllNdwomordanlged.l.adcoflobricatiol'l 81 high rpm is usuaIythe ca ..... oIdamage. lnsofI;c;ent oil or failure to cIlange theoil 81 the recornmeoded inUIrVaIII . . the chiefcaoS&S.Sinc.Iher.... _ _ ringsinlhe_d. no~

tjtowplug.,_irlgcyjltldertemperatllf"".lnsta~theponperheat

o

Coonectlngrodopperorlowereodcleatanc. «cessiwr . Caosed byexcesaive wear or lack of t.bication. Replace worn parts

"""'-.

other no'..

o o o o o o

o

CylinderheedgUlc.tleaking(Chapt"t~

El
over... evving)or~fforn..,_cyllnd ... component faiturn.Can.lsobealtribJladlodtopPngthem~on_of th.crankshatt.nds~ter2).

Engine rno<.OlIing bolts loose. Togtllen ail engine mount bolts /Chaptar2j Crankshaflbear/noSwom(Chapler2) Cam chain tensionerdef«:live. Replace (Chapt. 2) Camd>ain. sprodetsOlgLOdesworn (ChapterZ).

REF-36

Fault Finding

8 Abnormal driveline noise o

Clutch no;.. o

o o o

o

CIuIcnhouolngllric1iooplataclea1lncobCesaive(Chapter2j.

EngireoillewMtoolaw.CauseslhOWlIrOmIr iSsion. AIso ongne powerlllld cIu\l:::lIope
8~

l.DoHordamagedclltchpr
Bearlngos wom.AlsolncluOest hapossl biitylhatltleohafllae wom. ClYettIaulltletransmission(Chap\ef2) Gearswomorchipped(Chapler21 MeIaI chipajlmmedinOelll It4th·Prob8bIyPioonfromabroken cUtch.gearorshillrneo::n.>ismlhatwet1Opicked<4lbythepears. Thi..... caulWle;ortybearlngfllli ...... (Chept.2j

Fln8ldrlve nol..

o o o o

D

ChainnotadjusiedprOpefly(Olaplllrtj. FrontOtrearoprookolloose.Tlghtenfas*>erS{Chapter5~

SprocltetSWOO1. RepI_ sprockets (Chaptw 5).

F\ea,sproeMt warped. Rep/ac:esprockels(Chap\er5). WheelooupIing
9 Abnormal frame and suspension noise Lowfluldlev1llorImproperYisoDsltyoll L
o o

(ChapterS)

Bnrk. noI• •

Front 'IIId nohe

o o o o o

o

Spmg ___ or broI<M. ~al<es a clic:kO'lg orscrapingsouod. FOt1<

oiI , _drained.w. ha .... lotolmelalparticlesin~(Chapt .. 5).

$teeM!! head ~ loose or damaged . Oleks when

braking. Oleck and adjust orr9ptaoo as fl8CeIIsary (Chapten 1 anelS). F""'yokes loote. Mak1lSUl'8 .. ~ clampplnchbo/lS """1ght

(ChapterS)

Forkl<JbebeOt. Goodposoibilltyifmachirlflha.beendroppod. ~Wbewitha .-one(Ch"!)1er5)

o o o o

o

.~r

De~shockabsOtberwittl irrtemal~. This"inIh& Dody

oItheshock lndCeN!ll'l«!ied. lheshocl<mustbereplaced with . new one (CIIap!er 5).

withglazedpads.Cieanusingbnl k . cleaningso/Yenl~6).

Cootaminalionofbrak.pads.Oi.brak.nuk:lordi1eauslngbr....

to chaner or squeal. Clean or replace pads (Chapter6). Padsglazad .Causedby POI!Isslvel>oa!fromprolongeodUMor

wi"

d isc. A v wyHoeflatfllecanbeused.boIpad~tl.

o

suggested as 'cur' (Chapter 6~ Diacw8tj>ed.CancaUH . c/"Ialtering.clIcldngor;"tenniltent SQUe8I.Usually~byapuisatingleverand~

repair from a Kawasakidealer (Chapler5) D

Squuleausedbyp&d shim notiostaaedorpO$itioned~

(ChapIer6). Squea!causedbyduslonbrak.p&ds.UsuaIIyloo.ndtoge\her

CaJbOlundUmclOthorany Olherabrasiveto l"Ol9*" lhep&d surlaces asabrashtes stay in lhepad malotlal.nd damage Ihe

nol. .

A.lidlevlOirlcorreetIndicates a lNkea'*'
fChapter5). Looseorwomll1OlKltinga.O>&<:kandreplacaas.-led/Ct"olptefs)'

tromconhlrl'lkla.Iion. Oonot U5ll srodpapllr.emerycloth,

FrortalCle()faxJeclampboltlOose.rrg,tentMmtothe~

l
Shock

Ben! {)fdamagedshockbody.Rllplacelheehock....tth • .-one

o

brIIk1ng. Rep\aoelhlldisc(Chapler6) l.Ooteorwomwhfllllbearin<;ll-Chockand~.ceasr"lellded

!ChaPter 6).

10 Oil pressure light comes on Engine lubrlutlon .".,.",

o o

EngneoilpOO1pdeflC~ve. llklcI<edoil slrainer gauz. o'fafIed

rollet va ..... C..ryoutoilprassurecl>ecll(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

oIIfTom1hectarlnM (Chap!ef 2) o

C~ndersworn.cracked,orseontd.caUSedbyov.heatingOfoil

starvation. Thecy\indeBwil have 10 bereboreClanclnewpistona

Ins!alled{Chapt«2).

.

o

Mainjetloo~orloolle.ComPllf'l!h .. ;.tsiuIOIhIl

Specillcatlons(Chapter3) Chok.ca~eorliricage_ltsluck.causingfueitobepuiled

II'roughchcl