1982 AND LATER SERVICE INFORMATION
carburetor bodies and insert the shaft
through each plunger lever and spring.
Install the 4 circlips onto the choke
Check that the choke shaft operates
properly. It should slide from left to
resistance. When the shaft is pushed to
the off position, the plunger lever
springs must be compressed slightly to
push the plungers against their seat.
the plunger levers do not seat
properly, the air-fuel mixture will be
incorrect. Engine damage could result.
Visually synchronize the throttle valve
plates so that they each have an equal
gap at the throttle bore when closed. If
necessary, loosen the adjuster locknuts,
turn the adjusters as required and
tighten the locknuts.
Cleaning and Inspection
1. Thoroughly clean and dry all parts. If a
special carburetor cleaning solution is used,
all non-metal parts must be removed (gaskets,
O-rings, plastic plugs, etc.).
2. Blow out all the passages and jets with
compressed air. Don't use wire to clean any of
the orifices; they will be damaged and the
carburetor may be ruined.
Check the cone of the float needle (Figure
44) and replace if it is scored or pitted.
4. Examine the end of the pilot (idle mixture)
screw for grooves or roughness. Replace it if
5. Check all O-rings and plastic plugs for
damage and replace as necessary.
pin-holes or other damage. Replace. if
(ZX550-A1 A N D A2)
When removing the fuel tank on ZX550
models with the evaporative emission control
system, disconnect the breather and return
hose at the fuel tank. Plug the return hose
with a golf tee. These steps will prevent
gasoline from flowing out of the fuel tank.
(ZX550-A1 A N D A2)
models sold in
California are equipped with a evaporative
emission control system to conform with
state and government emission requirements.
The system is shown in Figure
evaporative emission control system routes
fuel vapors from the fuel system into the
engine (during operation) and then stores the
vapors in a special canister when the engine is
While no adjustments are required to
maintain the evaporative emission control
system, all hoses and parts should be
miles for loose or
damaged parts. Repair or replace parts as
solvent, gasoline or water enters the
canister, the canister's vapor absorbing
capacity is reduced and it must be
If the liquidhapor separator is removed
from its mounting position, do not lay the
separator on its side; always place it in its
upright mounting position.
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