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Safety First; Expendable Supplies - Kawasaki KZ500 Manual

1979-1985.
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GENERAL
INFORMATION
3
Frozen or very tight bolts and screws can
often be loosened by soaking with penetrating
oil like Liquid Wrench or WD-40, then sharply
striking the bolt head a few times with a ham-
mer and punch (or screwdriver for screws).
Avoid heat unless absolutely necessary, since it
may melt, warp, or remove the temper from
many parts.
Avoid flames or sparks when working near a
charging battery or flammable liquids, such as
gasoline.
No parts, except those assembled with a press
fit, require unusual force during assembly. If a
part is hard to remove or install, find out why
before proceeding.
Cover all openings after removing parts t o
keep dirt, small tools, etc., from falling in.
When assembling two parts,
start all
fasteners, then tighten evenly.
Wiring connections and brake shoes, drums,
pads, and discs and contact surfaces in dry
clutches should be kept clean and free of grease
and oil.
When assembling parts, be sure all shims and
washers are replaced exactly as they came out.
Whenever a rotating part butts against a sta-
tionary part, look for a shim or washer. Use
new gaskets if there is any doubt about the con-
dition of old ones. Generally, you should apply
gasket cement to one mating surface only, so
the parts may be easily disassembled in the
future. A thin coat of oil o n gaskets helps them
seal effectively.
Heavy grease can be used t o hold small parts
in place if they tend to fall out during assembly.
However, keep grease and oil away from elec-
trical, clutch, and brake components.
High spots may be sanded off a piston with
sandpaper, but emery cloth and oil d o a much
more professional job.
Carburetors are best cleaned by disas-
sembling them and soaking the parts in a com-
mercial carburetor cleaner. Never soak gaskets
and rubber parts in these cleaners. Never use
wire to clean out jets and air passages; they are
easily damaged. Use compressed air t o blow out
the carburetor, but only if the float has been
removed first.
Take your time and d o the job right. D o not
forget that a newly rebuilt engine must be
broken in the same as a new one. Refer to your
owner's manual for the proper break-in pro-
cedures.
SAFETY FIRST
Professional mechanics can work for years
and never sustain a serious injury. If you
observe a few rules of common sense and
safety, you can enjoy many safe hours servicing
your motorcycle. You could hurt yourself or
damage the motorcycle if you ignore these
rules.
1. Never use gasoline a s a cleaning solvent.
2. Never smoke o r use a torch in the vicinity of
flammable liquids such as cleaning solvent in
open containers.
3. Never smoke or use a torch in an area where
batteries are being charged. Highly explosive
hydrogen gas is formed during the charging
process.
4. Use the proper sized wrenches to avoid
damage t o nuts a n d injury to yourself.
5. When loosening a tight or stuck nut, be
guided by what would happen if the wrench
should slip. Protect yourself accordingly.
6. Keep your work area clean and uncluttered.
7. Wear safety goggles during all operations in-
volving drilling, grinding, or use of a cold
chisel.
8. Never use worn tools.
9. Keep a fire extinguisher handy and be sure it
is rated for gasoline (Class B) and electrical
(Class C) fires.
EXPENDABLE SUPPLIES
Certain expendable supplies are necessary.
These include grease, oil, gasket cement, wiping
rags, cleaning solvent, and distilled water.
Also, special locking compounds, silicone
lubricants, and engine and carburetor cleaners
may be useful. Cleaning solvent is available at
most service stations and distilled water for the
battery is available at supermarkets.
SHOP TOOLS
For complete servicing and repair you will
need a n assortment of ordinary hand tools
(Figure 1).
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