1991 kawasaki GPZ 500 S - GPX 500 R - Answered Questions & Fixed issues
Starter stuck on kawasaki GPZ500
Remove the starter and test it out of the bike. The solinoid could be weak and not strong enough to pull the bendix back off of the flywheel. It could be adjusted too close to the flywheel and causing it to bind. In either case you are going to have to remove the starter, to find out why it sticks, and/or to replace it. First though, put it in 1st gear and rock it back and forth while listening for the bendix to release. The bendix spring could be broken/weak. Let me know if you have additional information or I can be of further assistance. Good luck, and please let me know how it goes!
Water in the oil
Check cylinder head and base gaskets. L and R Cover gaskets and fittings.
Stalling when starting
I would check that the rubber seals for the Choke circuit are in good shape and that the choke is actually working properly.
Wires are disconnected on my Kawasaki GPZ 500, I
Wires are color coded > red to red, blue to blue, etc.. As to where to connect each wire, just go to the dealer and ask to see a wireing diagram. Unless he is a **** he will be glad to help. Other options include the library for a service manual, purchase a service manual, Google 'Kawasaki GPZ 500 wireing', and finding another GPZ500 and looking at it's wireing.
Sprockets
when you change a sprocket, you change the chain as this will lead to premature sprocket failure
Cam shaft bolt tourge settings
if you mean tightness of the belt itself, you should just be able to twist it 90degrees when under tension on the longest run of the belt
Gpx 500 with misfire on 1 cylinder.
carb pilot/main jet blocked.
check ignition wiring ie wires to coils is anything lose
check tappet clearance
get a compression test done to ensure the engine is OK
hope this helps
Starting
The sprocket behind the flywheel has a roller clutch. Very simple but difficult to describe, maybe you could google it. Its a common clutch arrangement used on many starters. They can often fill up with **** from the oil and the small rollers and springs inside don't move freely. If this is the problem then it only needs cleaning out and I usually give the springs a little stretch. ie. another millimeter is plenty. Sometimes a spring may be broken. The only way to find out whats really wrong is to take it apart but you will need the correct puller to remove the flywheel. Its basically impossible to do this job without the right tools.
Change fork seals Kawasaki GPZ 400
If you are not VERY mechanically inclined...and have the special tools required... .please take this to a professional!! it will be less expensive in the long run.!!
It takes some special tools that only dealers have.
I lost my key to
Before you attempt to take out the ignition, call a dealer and ask him if they can get you a key for your bike by using the VIN as reference. Harley and some metrics can do it this way.
No fire to the motor
check coil or wire from coil. could be blown fuse or bad brain...aka CDI in which case you could open it after locating it and possibly discover a bloated capacitor which you can snip off and solder in a new one for 2 bucks. at a radio shack or electronics parts store
Motorbike wont move
sidestand lockout switch is sticking...bike thinks that you're trying to ride away with the stand down so it kills the sparks.
How do u no if ur coil packs are fireing
If you have a wiring diagram, trace out the ignition system this way you trace problems. But you could pull the plugs and put them in the wire and ground it against the head, away from the spark plug hole, turn the engine over and see if it fires, i use a spark tester, but a known good plug will do. If there is no spark then check to see if you have volts at the primary side of coil "the little wires that hook to it test them with the ignition on" if no volts there then begin your volt chace checking all wire and connectors. You will need a multi meter ok. let me know how it goes, just takes patience and time k.
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