1982 AND LATER SERVICE INFORMATION
red 6-pin connector and the appropriate
d. If the readings are all as specified, test
the individual sensors as described in
the following steps.
3. To test the sidestand switch:
a. Disconnect the leads at the switch.
Connect an ohmmeter (set atX1)
between the leads.
b. With the sidestand up, the meter should
read zero ohms (no resistance).
c. With the sidestand down, the meter
should read infinite resistance.
d. If the switch does not perform as
described, make sure it is properly
mounted on the frame. If it is properly
mounted but the readings are not as
specified, replace the switch.
4. To test the oil level sensor:
a. Drain the engine oil as described in
Chapter Three of the main book and
remove the oil level sensor.
b. Connect an ohmmeter (set atX1)
between the sensor lead and the sensor
c. With the sensor held upright (Figure 57),
the ohmmeter should read no continuity
(infinite resistance). With the sensor
held upside down (Figure 57), the
ohmmeter should read less than 0.5
d. If the readings are not as specified,
replace the oil level sensor.
5. To test the battery electrolyte level sensor:
a. Remove the seat and disconnect the
pink lead from the sensor.
b. Set a voltmeter at the 10V range.
Connect the voltmeter positive lead to
the sensor lead; connect the voltmeter
negative lead to the frame (chassis
c. The voltmeter should read more than 6
volts. If it reads less, check the battery
electrolyte level. Make sure the sensor is
installed in the correct battery cell as
indicated by the arrow on the battery
case. Pull the sensor out of the battery
and check it for corrosion or other
damage; replace if damage is found.
6. To test the fuel level sensor:
a. Remove the fuel tank and remove the
sensor from the tank as described in
Chapter Seven of the main book.
b. Check that the float operates smoothly
and that the tank walls do not interfere
with its operation. The float should
move downward under its own weight.
If not, or if the sensor shows any
mechanical damage, replace it.
c. Connect an ohmmeter between the
sensor leads. With the float at its highest
position (as with a full tank), the
ohmmeter should read 1-5 ohms. With
the float at its lowest position (as with
an empty tank), the ohmmeter should
read 103- 1 17 ohms.
d. If the readings are not as specified or if
the readings d o not change smoothly as
the float is moved, replace the sensor.
WARNING LIGHT SYSTEM
(1984-ON ZX550-A1 AND A2)
The gauge and warning light system
monitors critical operating circuits on the
motorcycle. The system consists of a liquid
crystal display (LCD) combined with a red
light emitting diode (LED) warning light to
monitor the engine oil level, fuel level, battery
electrolyte level and sidestand position.
Gauge and Warning System Test
The following test assumes the battery is
fully charged. Refer to Figure 59.
1. Remove the fuel tank to gain access to the
warning system connector under the fuel
2. Connect a voltmeter to the motorcycle half
of the warning system wiring harness as
a. Voltmeter positive
lead to the
b. Voltmeter negative
lead to the
3. Turn on the ignition switch. The voltmeter
must indicate battery voltage. If battery
voltage is not present in the warning system
wiring harness, check for a bad connection or
a broken wire. If battery voltage is present at
the connector, continue this procedure.
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