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Service Hints - Kawasaki KZ500 Manual

1979-1985.
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Table of Contents
2
CHAPTER ONE
CAUTION
is used to emphasize areas where
equipment damage could result if proper
precautions are not taken. A
W A R N I N G
is used to
stress those areas where personal injury or
death could result from negligence, in addition
to possible mechanical damage.
SERVICE HINTS
Time, effort, and frustration will be saved
and possible injury will be prevented if you
observe the following practices.
Most of the service procedures covered are
straightforward and can be performed by
anyone reasonably handy with tools. It is sug-
gested, however, that you consider your own
capabilities carefully before attempting any
operation involving major disassembly of the
engine.
Some operations, for example, require the
use of a press. It would be wiser to have these
performed by a shop equipped for such work,
rather than to try t o d o the job yourself with
makeshift equipment. Other procedures require
precision measurements. Unless you have the
skills and equipment required, it would be bet-
ter to have a qualified repair shop make the
measurements for you.
Repairs go much faster and easier if the parts
that will be worked on are clean before you
begin. There are special cleaners for washing
the engine and related parts. Brush or spray on
the cleaning solution, let stand, then rinse it
away with a garden hose. Clean all oily or
greasy parts with cleaning solvent as you
remove them.
W A R N I N G
Never use gasoline as a cleaning agent.
It presents an extreme fire hazard. Be
sure to work in a well-ventilated area
when using cleaning solvent. Keep a fire
extinguisher, rated for gasoline fires,
handy in any case.
Much of the labor charge for repairs made by
dealers is for the removal and disassembly of
other parts to reach the defective unit. It is fre-
quently possible to perform the preliminary
operations yourself and then take the defective
unit in to the dealer for repair, at considerable
savings.
Once you have decided to tackle the job
yourself, make sure you locate the appropriate
section in this manual, and read it entirely.
Study the illustrations and text until you have a
good idea of what is involved in completing the
job satisfactorily. If special tools are required,
make arrangements to get them before you
start. Also, purchase any known defective parts
prior to starting on the procedure. It is
frustrating and time-consuming to get partially
into a job and then be unable to complete it.
Simple wiring checks can be easily made at
home, but knowledge of electronics is almost a
necessity for performing tests with complicated
electronic testing gear.
During disassembly of parts keep a few
general cautions in mind. Force is rarely needed
to get things apart. If parts are a tight fit, like a
bearing in a case, there is usually a tool de-
signed
to
separate them.
Never use a
screwdriver to pry apart parts with machined
surfaces such as cylinder head or crankcase
halves. You will mar the surfaces and end up
with leaks.
Make diagrams wherever similar-appearing
parts are found. You may think you can
remember where everything came from
-
but
mistakes are costly. There is also the possibility
you may get sidetracked and not return to work
for days or even weeks
-
in which interval,
carefully laid out parts may have become
disturbed.
Tag all similar internal parts for location,
and mark all mating parts for position. Record
number and thickness of any shims as they are
removed. Small parts such as bolts can be iden-
tified by placing them in plastic sandwich bags
that are sealed and labeled with masking tape.
Wiring should be tagged with masking tape
and marked as each wire is removed. Again, do
not rely o n memory alone.
Disconnect battery ground cable before
working near electrical connections and before
disconnecting wires. Never run the engine with
the battery disconnected; the alternator could
be seriously damaged.
Protect finished surfaces from physical
damage or corrosion. Keep gasoline and brake
fluid off painted surfaces.
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Zx550Kz550Kzx550

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