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Table of Contents
CHAPTER FOUR
.................................................................................................................................
ENGINE
70
Tools
Engine design
Break-in
Servicing engine in frame
Cam chain and tensioner
Valve cover
Camshaft
Cylinder head
Valves and guides
Cylinder block
Pistons and rings
Oil cooler
Removal/installation
Oil filter bypass valve
Oil pump
Crankcase
Secondary shaft and starter clutch
Crankshaft and connecting rods
Cam chain inspection
Primary chain inspection
Crankcase assembly
CHAPTER FIVE
CLUTCH
............................................................................................................................
124
Operation
Clutch release mechanism
Clutch
CHAPTER SIX
TRANSMlSSlON
....................
. .
.......................................................................................
133
Sprocket cover
Neutral switch
Engine sprocket
Shift linkage
Shift detent
Transmission
Shift drum and forks
Transmission gears
CHAPTERSEVEN
...................................................................................
FUEL AND EXHAUST SYSTEMS
148
Carburetor operation
Carburetor troubleshooting
Rejetting
Carburetor tuning
Carburetor service
Fuel level inspection
Idle mixture adjustment
(Non-U.S. models)
Fast idle adjustment
Crankcase breather
Air suction system
(U.S. models)
Fuel tank
Fuel tap
Fuel level sending unit
Exhaust system
CHAPTER EIGHT
......................................................................................................
ELECTRICAL SYSTEM
169
Wiring diagrams
Fuses
Battery
Ignition system
Contact breaker points and
condenser service
Spark plugs
Ignition advance mechanism
Ignition coil
Pickup coils
(Transistorized ignition)
Alternator stator
Alternator rotor
Starting system
Starter motor
Starter clutch
Starter solenoid
Lighting system
Turn signal cancelling system
Fuel level sensor
Fuel gauge
Horn
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Table of Contents

   Also See for Kawasaki KZ500

This manual is also suitable for:

Zx550Kz550Kzx550

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