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1982 AND LATER SERVICE INFORMATION
285
Engine stop switch
p J
start. When the self-test is complete the
warning unit should apper as shown in Figure
60. If the self-test did not start or if any
malfunction exists in the display, the warning
unit is defective and must be replaced by a
Kawasaki dealer.
8. One by one disconnect the jumper wires
simulating the warning circuits (Step 5). The
LCD warning light should flash and the
warning display should flash for each
simulated malfunction. See Figure 61.
9. If the warning and gauge unit tests good
but a malfunction still exists when the unit is
connected to the motorcycle wiring harness, a
fault may exist in the wiring or connector.
Perform Connector and Wiring Test.
Connector and Wiring Test
The following test requires the use of a
VOM (volt-ohm-ammeter) as described in
Chapter One of the main book.
1. Perform Gauge and Warning System Test.
If the warning unit tests good, the following
test will check the main motorcycle harness
and sensor wiring. If the wiring and
connectors appear to be good, perform the
applicable
warning
sensor
test
under
Solid-state Gauge and Warning Light Panel
(KZ550-HI) in this supplement to determine
if a particular sensor is defective.
NOTE
All
of
the following
test
steps
connections
are
made
on
the
motorcycle h a y of the gauge and
warning system connector.
2. Connect the leads of an ohmmeter
between the green/white wire and the
blacWyellow wires. The ohmmeter must
indicate
0
ohms when the sidestand is up and
continuity when the stand is down.
3. Connect the ohmmeter leads between the
blue/red
and
blacWyellow
wires.
The
ohmmeter must indicate less than 0.5 ohms
when the engine oil level is higher than the
minimum level mark on the oil level window.
The ohmmeter must indicate infinity when
the oil level is much lower than the minimum
level mark on the engine oil level window.
4. Connect the ohmmeter leads between the
yellow/black and blacWwhite wires. The
ohmmeter
must
indicate
1 - 1 17 ohms,
depending on the level of fuel in the tank (1 17
ohms for an empty tank).
5. Connect the positive
(+)
lead of the
voltmeter to the pink wire and the negative
(-)
lead of the voltmeter to the blacWyellow wire.
The voltmeter should indicate more than 6
volts when the battery electrolyte is above the
minimum level mark and
0
volts when the
electrolyte is below the minimum level mark.
SWITCHES
(ZX550-A1 AND A2)
Switches can be tested with an ohmmeter
such as described in Chapter One or a battery
operated test light. Use the color wiring
diagrams at the end of this book to help in
locating and identifying the following switch
wiring terminal connectors.
Engine Stop Switch
Testing/Replacement
1. Disconnect the negative cable from the
battery.
2. Remove
the
headlight
assembly as
described in Chapter Eight of the basic book
and locate the switch wires in the shell.
3. Check the switch by testing its continuity
in each of the operating conditions (Figure
62).
4. If the switch is faulty, have it replaced by a
dealer or qualified specialist.
Ignition Switch
Testing/Replacement
1. Disconnect the negative cable from the
battery.
2. Remove
the
headlight
assembly as
described in Chapter Eight of the basic book
and locate the switch wires in the shell.
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