1985-1997 Kawasaki ZX500 Ninja ZX600 Motorcycle Repair Manual by Clymer

Description

This 1985-1997 Kawasaki ZX500 Ninja ZX600 Repair Manual by Clymer provides detailed service information, step-by-step repair instruction and maintenance specifications for 1985-1997 Kawasaki ZX600 Ninja and 1985-1990 Kawasaki ZX500 European motorcycles.

1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997

Includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, electrical system, frame and body. Features complete wiring diagrams and 330 illustrated pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Torque specifications / Fasteners / Lubricants / Parts replacement / Basic hand tools / Test equipment / Mechanic’s tips

CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Engine lubrication / Clutch / Transmission / Charging system / Starting system / Electrical problems / Ignition system / Excessive vibration / Carburetor troubleshooting / Front suspension and steering / Brake problems

CHAPTER THREE / PERIODIC LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Maintenance intervals / Tires / Battery / Periodic lubrication / Periodic maintenance / Suspension adjustment / Suspension adjustment / Tune-up / Electronic ignition / Carburetor

CHAPTER FOUR / ENGINE
Servicing engine in frame / Engine principles / Engine / Cylinder head cover and camshafts / Cam chain tensioner / Rocker arm assemblies / Cylinder head / Valves and valve components / Cylinder block / Piston and piston rings / Oil pressure relief valve / Oil pressure switch / Oil cooler / Secondary sprocket, shaft and starter motor clutch / Crankcase / Crankshaft / Connecting rods

CHAPTER FIVE / CLUTCH
Clutch / Clutch release mechanism

CHAPTER SIX / TRANSMISSION
Sprocket cover / Neutral switch / Engine sprocket / External shift mechanism / Shift detent / Transmission gears

CHAPTER SEVEN / FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS
Carburetor / Fuel level / Fuel tank / Fuel valve / Fuel level sensor / Air suction system (U.S. models) / Emission control / Exhaust system

CHAPTER EIGHT / ELECTRICAL SYSTEM
Alternator / Transistorized ignition / Electric starter / Lighting system / Switches / Wiring and connectors / Instrument cluster / Thermostatic fan switch / Water temperature sensor / Horn / Junction box and fuses / Wiring diagrams

CHAPTER NINE / COOLING SYSTEM
Cooling system inspection / Coolant reservoir / Radiator and fan / Thermostat / Water pump / Hoses / Thermostatic fan switch and water temperature sensor

CHAPTER TEN / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Wheel balance / Tubeless tires / Tubeless tire changing / Handlebars / Steering head / Brake plunger and anti-dive

CHAPTER ELEVEN / REAR SUSPENSION
Rear wheel / Rear hub / Rear sprocket and coupling / Drive chain / Wheel balancing / Tire changing and repair / Rear shock absorber / Rear swing arm

CHAPTER TWELVE / BRAKES
Disc brakes / Brake pad replacement / Brake calipers / Front master cylinder / Rear master cylinder / Brake hose replacement / Brake disc / Bleeding the system

CHAPTER THIRTEEN / FAIRING ASSEMBLY

SUPPLEMENT / 1988 AND LATER SERVICE INFORMATION
Periodic lubrication / Periodic maintenance / Suspension adjustment / Tune-up / Engine / Cylinder head cover and camshafts / Cylinder head / Oil cooler / Clutch release mechanism / External shift mechanism / Transmission gears / Fuel tank / Fuel valve / Air suction valve / Water temperature sensor (1989 and later models) / Junction box and fuses (1989 and later models) / Radiator and fan / Thermostat / Front wheel / Front forks / Electric suspension control system (ESCS) / Rear shock absorber / Brake pad replacement / Brake calipers / Bleeding the system / Front fairing

INDEX

WIRING DIAGRAMS