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Kawasaki KZ500 Manual Page 307

1979-1985.
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Table of Contents
1982 AND LATER SERVICE INFORMATION
297
A. Handlebar
B. Clamp bolt
C. Plug
D. Holder
E. Holder bolt
F. Positioning plate
the brake lever and push the plunger rod back
into the plunger body. The plunger rod must
move smoothly in both directions. If the rod
is stuck or does not move smoothly, replace
the brake plunger assembly.
4. Install the brake plunger assembly. Keep
the following points in mind:
a. Make sure the O-ring is in good
condition. Replace it if necessary.
b. Retighten the metal brake line fitting
and bleed the brakes as outlined in this
supplement.
Antidive Valve
Test/Removal/Installation
1. Remove the brake plunger assembly from
the anti-dive valve as described in this
section of the supplement.
2. Remove the
fork
tube
from
the
motorcycle. Remove the top bolt and remove
the main fork spring.
3. Tape over the air pressure equalizer hole
in the fork leg to keep the fork oil from
running out.
4. Hold the fork leg vertically and compress
the fork tube. Alternately press and release
the plunger rod in the anti-dive assembly as
the fork tube is compressed. The fork
compression should be noticeably stiffer
when the plunger rod is pressed than when
released. The extension (rebound) stroke of
the fork tube should be the same whether or
not the plunger is pressed. Replace the
anti-dive valve if it does not function
smoothly and correctly.
5. Installation is the reverse of removal.
Keep the following points in mind:
a. If the anti-dive valve was removed,
ensure the O-rings between the valve
assembly and the fork tube are in good
condition.
b. Install the fork spring and fork top bolt
and install the fork on the motorcycle.
c. Install the brake plunger assembly as
described
in
this section of the
supplement. Be sure to bleed the brakes.
HANDLEBARS AND HOLDERS
(KZ550-HI)
Refer to Figure 85 for these procedures.
1. To remove the left-hand handlebar:
a. Loosen the bolt securing the clutch
lever.
b. Remove
the
screws
holding
the
left-hand switch housing together and
separate the housing.
c. Remove the handlebar clamp bolt and
end plug. Pull the handlebar out of the
holder.
2. To remove the right-hand handlebar:
a. Loosen the front master cylinder clamp
bolts.
b. Remove
the
screws
holding the
left-hand switch housing together and
separate the housing.
c. Remove the throttle grip.
d. Remove the handlebar clamp bolt and
plug. Pull the handlebar out of the
holder.
3. To remove either handlebar holder:
a. Remove the screws securing the steering
stem head cover and remove the cover.
b. Remove the rubber cap covering the
handlebar holder bolt.
c. Remove the handlebar holder bolt, the
positioning plate Allen bolt and the
positioning
plate.
Remove
the
handlebar holder.
4. Install the handlebar holder onto the
steering stem head as follows:
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