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Contact Breaker Points - Kawasaki KZ500 Manual

1979-1985.
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Table of Contents
LUBRICATION, MAINTENANCE AND TUNE-UP
57
this procedure and install the removed parts.
9. Install the valve cover; see
Valve Cover
Installation in Chapter Four.
10. Install the fuel tank; see
F u e l T a n k
Installation in Chapter Seven.
Adjustment
To adjust the valve clearance, the camshaft
must be removed and the shim under the valve
lifter must be removed and replaced with one
of a different thickness. T h e shims are
available from Kawasaki dealers in increments
of 0.05 mm and range in size from 2.0-3.2 mm
(shim No. 200 to s h i m N o . 320). T h e
dimension is often marked on the bottom shim
surface.
This procedure pertains only to valves that
need adjustment. Do not remove any shims on
valves whose clearance falls within the
specified range.
1. Remove the camshaft with valve clearances
to be adjusted; see C a m s h a f t R e m o v a l in
Chapter Four.
2. Remove the lifter (A, Figure 68).
C'A I'TION
Be very careful not to darnage the outer
surface ofthe lifter. Use a rubber suction
cup, rfavarlable, to pull the llfter out.
3. Remove the shim (B, Figure 68). Check the
thickness marked on it or measure the shim
thickness with a micrometer.
4. Calculate the correct shim thickness using
this example. Refer to Table
3
for the specified
clearance.
NOTE
The followrng nurnbers are.for exatnple
onlv.
Example:
Actual measured clearance
..........
0.52 mm
Subtract specified clearance
.......
-0.15 m m
Equals excess clearance
................
0.37 mm
Existing shim number
..........................
220
Add excess clearance
...........................
+
37
Equals new shim number
.....................
257
(round up to
the nearest shim number)
.................
260
5. Insert the new shim under the valve lifter.
CA I'TION
Never put shrm stock under u shrtn. The
shrtn could cotne loose at h g h rptn and
came
extensive
engrne darnage. N e w
grind the shrrn; thrs can remove the
hardened outer shrtn suvface and cuusea
,fractlrre and extensrve engrrie datnage.
NOTE
I f the stnallest uwrlahle shrtn does not
rncrease clearance to wrthrn acceptable
lrtnrts, the valw seat rsprobablv worn. I f
thrs rs the case, repair the valve seat,
grrnd the valve stem sl~ghtlj~ and recheck
t h e c l e a r a n c e . S e e
V a l v e / S e a t
Inspection
In Chapter Four.
CA UTION
Do not rnsert the earn churn tensroner
cross wedge lint11 after the valve cowr
and rts c h a ~ n guide are rnstulled and the
tensloner assetnbly
I S
rnstalled on the
cvl~nder block.
6. Install t h e c a m s h a f t ; see
C a m s h a f t
Installation in Chapter Four.
7. Install the valve cover; see
Valve Cover
Installation in Chapter Four.
8.
Install the fuel tank: see Fuel T a n k
Installation in Chapter Seven.
CONTACT
BREAKER
POINTS
A contact breaker point ignition is used on
early models (Figure 69). During normal
operation, the contact surfaces of the points
gradually erode and become contaminated.
The point rubbing block also wears, retarding
ignition timing. Periodic cleaning and gap
adjustment is required to keep the engine
operating at peak efficiency.
Inspection
1. Check that the ignition switch is OFF.
2. Remove the spark plugs.
3. Remove the ignition timing cover and
gasket.
4. Inspect the contact point surfaces (Figure
70). If the points are not badly pitted they can
be removed and dressed with a few strokes
from a point file; Flexstone is a good brand to
use. If the contact surfaces are badly pitted,
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Zx550Kz550Kzx550

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