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ENGINE
101
d e s c r i b e d i n t h i s c h a p t e r . Follow the
Installation procedures when given separately
or reverse the Removal procedures when
separate installation procedures are not given.
Do not omit any steps. Note the following.
a. Secure the ignition timing leads in the
clamps attached to the lower right side of
the engine (Figure 95).
b. Route the alternator and starter leads
behind the shift mechanism cover tabs
(Figure 96).
c. After connecting multiple-pin plastic
connectors, make sure none of the male
pins have popped out of place. Tug on the
wires to find a loose pin and push loose
pins back into place until you feel the
locking tang seat fully.
d. The oil pressure switch lead is bluelred.
e. The neutral switch lead is light green.
f. The rear brake light switch leads are blue
and brown.
g. The No. 1 and 4 ignition coil goes on the
left. The black lead goes to the left coil
and the green lead goes to the right coil.
The yellowhed wires can go to either coil
terminal.
h. Check that the engine oil drain plug is
torqued as specified in Table 2 and add
engine oil to the crankcase; see Engine Oil
and Filter in Chapter Three.
i. Adjust the throttle cables, ignition timing
(on contact breaker point models), clutch,
drive chain, rear brake and rear brake
light switch as described in Chapter
Three.
WARNING
Make sure none of the control cables or
wires are stretched or pinched when the
handlebars are turned.from lock to lock.
CAUTION
Do not hurry t o start or ride the
motorcycle
yet. You have invested a lot
of time, energy and money at this point.
Do not take a chance on serious injury or
mechanical damage. Thoroughly check
and recheck all parts and controls on the
motorcycle. Make sure all cables are
correctly routed, adjusted and secured
and all bolts and nuts are properly
tightened. Position all cables away from
the exhaust system.
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   Also See for Kawasaki KZ500

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Zx550Kz550Kzx550

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